Mold assembly, composite abrasive belt, and method of making the same

Abstract

The application provides a mold assembly, a composite abrasive belt and a preparation method thereof. The mold assembly comprises abrasive rollers, abrasive particle pressing rollers and belt conveying rollers arranged in parallel with each other. The abrasive belt substrate is clamped between the abrasive rollers and the belt conveying rollers. The abrasive particle pressing rollers are arranged side by side with the abrasive rollers along the direction of the plane of the abrasive belt substrate. The roller surface of the abrasive particle pressing roller and the roller surface of the abrasive roller are oppositely arranged with a preset interval. The roller surface of the abrasive roller is provided with a plurality of abrasive particle grooves. The inside of the abrasive roller is provided with a plurality of cavities arranged in the circumferential direction and extending in the axial direction. The plurality of cavities are filled with heat-conducting liquid. When the abrasive layer is demolded from the abrasive roller, the hydraulic pressure of the heat-conducting liquid corresponding to the demolding area is controlled to make the roller surface of the abrasive roller corresponding to the demolding area elastically deform. The abrasive layer can be quickly demolded from the abrasive roller under the deformation of the roller surface of the abrasive roller, so as to solve the problem of difficult demolding of the abrasive particles and realize the continuous production of the composite abrasive belt.

Description

Technical Field

[0001] This invention relates to the field of abrasive belt technology, and in particular to a mold assembly, a composite abrasive belt, and a method for preparing the same. Background Technology

[0002] Currently, with the rapid development of cutting-edge technologies such as aerospace instruments and precision equipment, and semiconductor chips, efficient and precise grinding technology for materials has become a key bottleneck restricting the development of high-end manufacturing. Among these technologies, abrasives are the most influential factor on processing quality in the field of grinding. Traditional single-grain grinding has low efficiency and poor workpiece surface quality, making it difficult to meet the development needs of high-precision, high-speed, and high-efficiency grinding technologies.

[0003] Composite abrasives are a type of composite abrasive material, consisting of multiple tiny abrasive particles bonded together by an adhesive to form an independent abrasive composite of a specific shape and size. They offer significant advantages in high-efficiency and high-quality grinding. However, the innovation and development of composite abrasive belts are currently not ideal, especially regarding the insufficient research and development of specialized abrasive belts for wood processing. The following problems exist: the belt preparation process is cumbersome and complex; the abrasive particle clusters after breakage have poor uniformity in shape, affecting the stability and uniformity of the belt during grinding, thus impacting grinding quality and processing accuracy. To address this, a fixed-configuration abrasive belt has been proposed. While this fixed-configuration belt can arrange composite abrasive particles regularly on the belt surface to improve grinding performance, it employs a pre-forming and post-granulation process. This process limits the degree of automation in production, making large-scale automated production difficult and unable to meet the large market demand for composite abrasive belts for wood processing. Furthermore, if a pre-granulation and post-forming process is adopted, the technical challenge of abrasive particle demolding remains.

[0004] Therefore, it is necessary to provide a new technical solution to solve the above-mentioned technical problems. Summary of the Invention

[0005] This invention provides a mold component, a composite abrasive belt, and a method for preparing the same, in order to solve the problems of difficult demolding of abrasive particles and inability to achieve continuous production in the existing composite abrasive belt manufacturing process.

[0006] This invention provides a method for preparing composite abrasive belts, comprising the following steps: Step 1: Mix the abrasive grains with the adhesive and let it stand to obtain the mixed abrasive. Step 2: Provide a mold assembly, including an abrasive roller, an abrasive pressure roller, and an abrasive belt conveyor roller arranged parallel to each other. The abrasive belt substrate is sandwiched between the abrasive roller and the abrasive belt conveyor roller. The abrasive pressure roller and the abrasive roller are arranged side by side along the plane of the abrasive belt substrate, and the roller surface of the abrasive pressure roller is positioned opposite the roller surface of the abrasive roller at a preset distance. The roller surface of the abrasive roller has a plurality of abrasive grooves arranged in a preset pattern. The interior of the abrasive roller has a plurality of circumferentially arranged and axially extending cavities, and each of the cavities is filled with a heat-conducting liquid. Spatially, the area corresponding to the abrasive roller and the coating equipment is the coating area, the area corresponding to the abrasive roller and the abrasive pressure roller is the granulation area, and the area corresponding to the abrasive roller and the abrasive belt substrate is the demolding area. The coating area, the granulation area, and the demolding area are continuous areas. Step 3: Drive the abrasive roller and the abrasive pressure roller to rotate in opposite directions. Use the coating equipment to coat the roller surface of the abrasive roller entering the coating zone with the mixed abrasive. The mixed abrasive on the abrasive roller forms an abrasive layer after being rolled by the abrasive pressure roller in the granulation zone. During this process, the hydraulic pressure of the heat-conducting fluid corresponding to the coating zone and the granulation zone is controlled to be less than or equal to a preset threshold so that the roller surface corresponding to the coating zone and the granulation zone remains flat. Step 4: Apply a primer to the surface of the abrasive belt substrate; Step 5: Drive the abrasive belt conveyor roller and the abrasive roller to rotate in opposite directions. The abrasive belt conveyor roller drives the abrasive belt substrate to move in an axial direction perpendicular to the abrasive belt conveyor roller, so that the abrasive belt substrate contacts the abrasive roller in the demolding zone. At the same time, pressurize the heat-conducting liquid corresponding to the demolding zone to a hydraulic pressure greater than the preset threshold, so that the roller surface corresponding to the demolding zone undergoes elastic deformation, so that the abrasive layer is demolded from the abrasive roller and the abrasive layer is tightly bonded to the abrasive belt substrate, thereby obtaining a composite abrasive belt.

[0007] Optionally, the preset threshold is a critical pressure value that causes the surface of the abrasive roller to undergo elastic deformation.

[0008] Optionally, a scraper is further provided between the roller surface of the abrasive pressure roller and the roller surface of the abrasive roller, and the step of forming an abrasive layer by the mixed abrasive on the abrasive roller after being rolled by the abrasive pressure roller in the grinding zone includes: The mixed abrasive entering the grinding zone is leveled by a scraper. After leveling, the mixed abrasive is then rolled by the abrasive pressure roller so that the abrasive groove at the corresponding position is filled with the mixed abrasive, forming an abrasive layer of a preset thickness.

[0009] Optionally, before coating the roller surface of the abrasive roller entering the coating zone with the mixed abrasive, the following steps are further included: A release agent is sprayed onto the surface of the abrasive roller that enters the coating zone.

[0010] Optionally, after the abrasive layer is formed by the abrasive roller and before the primer is applied to the surface of the abrasive belt substrate, the following steps are further included: The heat-conducting liquid corresponding to the abrasive layer is heated and maintained at 60°C for 1 minute to preliminarily shape the abrasive layer.

[0011] Optionally, a cleaning zone is further provided between the coating zone and the demolding zone in terms of spatial location. The coating zone, the granulation zone, the demolding zone, and the cleaning zone are sequentially connected continuous areas. After step 5, the following steps are also included: The surface of the abrasive roller entering the cleaning zone is cleaned. Repeat steps 3 through 5.

[0012] Optionally, after obtaining the composite abrasive belt, the following steps are also included: The composite abrasive belt was dried at 70°C for 20 minutes and then dehumidified. The composite abrasive belt is dried again at 90°C for 40 minutes to complete the shaping process.

[0013] Optionally, the mixed abrasive is prepared by mixing the abrasive grains and the adhesive in a 1:3 ratio, and the adhesive is prepared by mixing polyurethane emulsion and phenolic resin adhesive in a 1:20 ratio.

[0014] The present invention also provides a composite abrasive belt, which is made by the above-mentioned method for preparing composite abrasive belt. The composite abrasive belt includes a belt substrate and an abrasive layer disposed on the surface of the belt substrate. The surface of the abrasive layer is provided with grinding units protruding along the surface of the belt substrate, and a gap is provided between adjacent grinding units.

[0015] The present invention also provides a mold assembly for preparing composite abrasive belts, comprising an abrasive roller, an abrasive pressure roller, and a belt conveyor roller arranged parallel to each other, wherein the belt substrate is sandwiched between the abrasive roller and the belt conveyor roller, the abrasive pressure roller and the abrasive roller are arranged side by side along the plane of the belt substrate, and the roller surface of the abrasive pressure roller and the roller surface of the abrasive roller are arranged relative to each other at a preset distance; The abrasive roller has a plurality of abrasive grooves arranged in a preset pattern on its roller surface, and the abrasive roller has a plurality of circumferentially arranged and axially extended cavities inside, each of which is filled with a heat-conducting liquid.

[0016] The above-described technical solution of the present invention has the following beneficial effects: The mold assembly, composite abrasive belt, and their preparation method provided by this invention utilize multiple circumferentially arranged and axially extended cavities inside the abrasive roller, each filled with a heat-conducting liquid. During the coating and rolling of the mixed abrasive, the hydraulic pressure of the heat-conducting liquid corresponding to the coating area and the grinding area is controlled to keep the roller surface of the abrasive roller in the corresponding area flat. When the abrasive layer is demolded from the abrasive roller, the hydraulic pressure of the heat-conducting liquid corresponding to the demolding area is controlled to cause elastic deformation of the roller surface of the abrasive roller in the corresponding demolding area. Under the deformation of the roller surface, the abrasive layer can be quickly demolded from the abrasive roller, making the abrasive layer tightly bonded to the abrasive belt substrate, thereby solving the problem of difficult demolding of abrasive particles and realizing the continuous production of composite abrasive belts. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in this 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 some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0018] Figure 1 This is one of the structural schematic diagrams of the mold assembly provided in an embodiment of the present invention; Figure 2 This is a second schematic diagram of the structure of the mold assembly provided in an embodiment of the present invention; Figure 3 A flowchart illustrating the preparation method of the composite abrasive belt provided in an embodiment of the present invention; Figure 4 A cross-sectional schematic diagram of the composite abrasive belt provided in an embodiment of the present invention; Figure 5 This is a planar schematic diagram of the composite abrasive belt provided in an embodiment of the present invention.

[0019] Figure label: 1. Abrasive roller; 2. Abrasive pressure roller; 3. Abrasive belt conveyor roller; 4. Abrasive belt substrate; 5. Coating equipment; 6. Scraper; 7. Abrasive layer; 8. Abrasive grains; 9. Adhesive; 10. Grinding unit; 101. Abrasive groove; 102. Cavity; 100. Coating area; 200. Pelletizing area; 300. Demolding area; 400. Cleaning area. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0021] With the increasing demands for grinding quality in precision machining, composite abrasive belts have attracted attention due to their high-efficiency grinding characteristics. Traditional abrasive belt manufacturing processes suffer from difficulties in abrasive grain demolding and cumbersome procedures. In particular, when using a pre-granulation followed by molding method, abrasive grains tend to stick to the mold, resulting in incomplete demolding and affecting the consistency of abrasive grain arrangement on the belt surface. Although existing fixed-configuration abrasive belts can achieve regular arrangement, they rely on a pre-molding followed by granulation process, which limits the feasibility of automated production.

[0022] Based on this, the present invention proposes a mold component, a composite abrasive belt and its preparation method to solve the problem of difficult demolding of abrasive particles, thereby realizing the continuous production of composite abrasive belts.

[0023] Please see Figure 1 and Figure 2 This invention provides a mold assembly for preparing composite abrasive belts with controllable abrasive grain morphology and arrangement. The mold assembly includes an abrasive roller 1, an abrasive pressure roller 2, and a belt conveyor roller 3 arranged parallel to each other. The belt substrate 4 can be sandwiched between the abrasive roller 1 and the belt conveyor roller 3. The abrasive pressure roller 2 and the abrasive roller 1 are arranged side by side along the plane of the belt substrate 4, and the roller surface of the abrasive pressure roller 2 is positioned opposite the roller surface of the abrasive roller 1 at a preset distance. The roller surface of the abrasive roller 1 is provided with a plurality of abrasive grooves 101 arranged in a preset pattern. The interior of the abrasive roller 1 is provided with a plurality of circumferentially arranged and axially extending cavities 102, each of which is filled with a heat-conducting liquid (not shown).

[0024] Spatially, the area corresponding to the abrasive roller 1 and the coating equipment 5 is the coating zone 100; the area corresponding to the abrasive roller 1 and the abrasive pressure roller 2 is the grinding zone 200; the area corresponding to the abrasive roller 1 and the abrasive belt substrate 4 is the demolding zone 300; and the area opposite the grinding zone 200, between the demolding zone 300 and the coating zone 100, is the cleaning zone 400. The coating zone 100, grinding zone 200, demolding zone 300, and cleaning zone 400 are sequentially continuous areas. In the manufacturing process of the composite abrasive belt, the coating zone 100 corresponds to the coating process, the grinding zone 200 corresponds to the abrasive roller 2 pressing and filling process, the demolding zone 300 corresponds to the demolding process of the abrasive layer and the abrasive roller 1, and the cleaning zone 400 corresponds to the cleaning process of the abrasive roller 1 after demolding.

[0025] The purpose of maintaining a preset distance between the roller surface of the abrasive roller 2 and the roller surface of the abrasive roller 1 is to form an abrasive layer of a preset thickness. That is, the preset distance between the roller surface of the abrasive roller 2 and the roller surface of the abrasive roller 1 is equal to the thickness of the abrasive layer to be formed. This preset distance can be set according to the actual situation and is not limited here.

[0026] The abrasive groove 101 refers to the groove structure on the roller surface of the abrasive roller 1 used to accommodate a single composite abrasive grain (i.e., a single grinding unit). Specifically, it can be formed by laser engraving or chemical etching. The structural form of the abrasive groove 101 is consistent with the structural form of the grinding unit on the pre-made composite abrasive belt. The arrangement rule of the abrasive groove 101 is consistent with the preset arrangement rule of the grinding unit on the pre-made composite abrasive belt. By restricting the displacement of the abrasive grains in the abrasive groove 101, the consistency of the arrangement of the abrasive grains on the surface of the belt is ensured.

[0027] The cavity 102 refers to the sealed space inside the abrasive roller 1 and corresponding to several abrasive grooves 101. Specifically, it can be achieved by opening a through channel structure inside the abrasive roller 1. The cavity 102 is filled with heat-conducting liquid. By controlling the hydraulic pressure of the heat-conducting liquid in the cavity 102, the roller surface of the corresponding area of ​​the abrasive roller 1 can undergo elastic deformation.

[0028] It should be noted that, in order to facilitate the illustration of the structure of the cavity 102 in the accompanying drawings of the present invention, the view is shown from the perspective of a partial cross-section of the abrasive roller 1. In actual use, in order to ensure the sealing of the cavity 102, each cavity 102 is sealed by a sealing cap or other sealing structure.

[0029] The coating zone 100, the granulation zone 200, and the demolding zone 300 are spatial regions divided around the abrasive roller 1 along its circumference. Along the axial direction of the abrasive roller 1, the coating zone 100, the granulation zone 200, and the demolding zone 300 all extend across the entire surface of the abrasive roller 1.

[0030] Among them, the heat transfer fluid is a liquid with thermal conductivity, such as heat transfer oil, aqueous solution or liquid metal.

[0031] Specifically, during the preparation process, the abrasive roller 1 and the abrasive pressure roller 2 rotate towards each other, and the abrasive belt conveyor roller 3 rotates towards the abrasive roller 1. A coating device 5 is used to coat the roller surface of the abrasive roller 1, which enters the coating zone 100, with a mixed abrasive. The mixed abrasive on the abrasive roller 1 rotates to the grinding zone 200 under the rotation of the abrasive roller 1, and is then pressed by the abrasive pressure roller 2 to form an abrasive layer. During this process, the hydraulic pressure of the heat-conducting fluid corresponding to the coating zone 100 and the grinding zone 200 is controlled to be less than or equal to a preset threshold. When the hydraulic pressure is lower than or equal to the preset threshold, the pressure inside the cavity 102 is low, and the roller surface of the abrasive roller 1 maintains a rigid structure, that is, the roller surfaces corresponding to the coating zone 100 and the grinding zone 200 remain flat, ensuring accurate embedding of the abrasive particles and stable formation of the abrasive layer. The abrasive belt conveyor roller 3 drives the abrasive belt substrate 4 to move in an axial direction perpendicular to the abrasive belt conveyor roller 3, so that the abrasive belt substrate 4 contacts the abrasive roller 1 in the demolding zone 300. At the same time, the heat-conducting liquid corresponding to the demolding zone 300 is pressurized to a hydraulic pressure greater than a preset threshold, so that the roller surface corresponding to the demolding zone 300 undergoes elastic deformation, reducing the contact area between the roller surface of the abrasive roller 1 and the abrasive layer, promoting the demolding of the abrasive layer from the abrasive roller, so that the abrasive layer is tightly bonded to the abrasive belt substrate 4, thus producing a composite abrasive belt.

[0032] After the abrasive roller 1 is demolded, the roller surface entering the cleaning zone 400 can be cleaned. At the same time, the hydraulic pressure of the heat-conducting fluid corresponding to the cleaning zone 400 is controlled to be less than or equal to a preset threshold, so that the roller surface of the abrasive roller 1 corresponding to the area maintains a rigid structure. That is, the roller surface entering the cleaning zone 400 is restored to a flat state, so that the subsequent rotation into the coating zone 100 will not affect the coating process, thereby realizing the continuous production of composite abrasive belts.

[0033] It should be noted that in the coating zone 100, granulation zone 200, demolding zone 300, and cleaning zone 400, each zone corresponds to at least one cavity 102. Of course, in order to control the hydraulic pressure more precisely, multiple cavities 102 can be set for each zone. The hydraulic pressure of the heat transfer fluid in multiple cavities 102 can be controlled sequentially to achieve more precise demolding and improve product yield.

[0034] The preset threshold is the critical pressure value (i.e., the buckling critical stress) that causes the roller surface of the abrasive roller 1 to undergo elastic deformation.

[0035] It is understandable that the roller body between the cavity 102 of the abrasive roller 1 and the roller surface is a thin-walled structure with a certain thickness. The thickness of the thin-walled structure can be specifically set according to factors such as the material of the abrasive roller 1 and the roller pressure of the abrasive layer, so that it can support the roller pressure of the abrasive layer and undergo elastic deformation when the hydraulic pressure of the heat transfer fluid is greater than a preset threshold.

[0036] Among them, the abrasive roller 1 is made of a material with thermal conductivity, such as iron, copper, silver or alloy metals, but is not limited to this.

[0037] In some embodiments, the mold assembly further includes a scraper 6, which is disposed between the roller surface of the abrasive roller 2 and the roller surface of the abrasive roller 1. The scraper 6 is used to scrape and level the mixed abrasive entering the grinding zone 200. The scraped mixed abrasive is then rolled by the abrasive roller 2 to form an abrasive layer of a preset thickness.

[0038] This invention achieves adaptive deformation of the abrasive roller surface by controlling the hydraulic pressure of the heat-conducting fluid, so that no external mechanical force is required during the demolding process, reducing the risk of damage to the abrasive structure and solving the problem of difficult demolding of abrasive particles, thereby realizing the continuous production of composite abrasive belts.

[0039] The mold assembly provided by this invention for preparing composite abrasive belts solves the problem of difficult demolding caused by abrasive grain adhesion during the preparation process, achieving non-destructive separation of the abrasive layer from the mold. Simultaneously, the structural design of the abrasive roller ensures the controllability of the abrasive grain morphology and arrangement, avoiding the impact of inconsistent grinding unit shapes on grinding stability, thereby improving the processing quality and service life of the abrasive belt product.

[0040] Please see Figures 1-3 The present invention also provides a method for preparing composite abrasive belts, which uses the above-mentioned mold assembly and includes the following steps: Step 1: Mix the abrasive grains with the adhesive and let it stand to obtain the mixed abrasive.

[0041] Specifically, the mixed abrasive is made by mixing abrasive grains and adhesive in a weight ratio of 1:3. This ratio ensures that the adhesive can fully coat the abrasive grains to form a stable composite structure, while avoiding excessive adhesive that could cause the abrasive grains to stick to the mold surface during demolding.

[0042] The adhesive is made by mixing polyurethane emulsion and phenolic resin in a weight ratio of 1:20. This ratio utilizes the high bonding strength of phenolic resin to ensure the structural stability of the grinding unit and maintain the shape consistency of the grinding unit, while the flexibility of a small amount of polyurethane emulsion improves the release performance of the adhesive system.

[0043] Step 2: A mold assembly is provided, comprising an abrasive roller 1, an abrasive pressure roller 2, and an abrasive belt conveyor roller 3 arranged parallel to each other. An abrasive belt substrate 4 is sandwiched between the abrasive roller 1 and the abrasive belt conveyor roller 3. The abrasive pressure roller 2 and the abrasive roller 1 are arranged side-by-side along the plane of the abrasive belt substrate 4, and the roller surface of the abrasive pressure roller 2 is positioned relative to the roller surface of the abrasive roller 1 at a predetermined distance. The roller surface of the abrasive roller 1 is provided with a plurality of abrasive grooves 101 arranged according to a predetermined pattern, and the interior of the abrasive roller 1 is provided with a plurality of circumferentially arranged and axially extending cavities 10. 2. Multiple cavities 102 are filled with heat-conducting liquid; in terms of spatial position, the area corresponding to the abrasive roller 1 and the coating equipment 5 is the coating area 100, the area corresponding to the abrasive roller 1 and the abrasive pressure roller 2 is the granulation area 200, the area corresponding to the abrasive roller 1 and the abrasive belt substrate 4 is the demolding area 300, and the area on the opposite side of the granulation area 200, between the demolding area 300 and the coating area 100 is the cleaning area 400. The coating area 100, the granulation area 200, the demolding area 300 and the cleaning area 400 are sequentially continuous areas.

[0044] Step 3: Drive the abrasive roller 1 and the abrasive pressure roller 2 to rotate in opposite directions. Use the coating equipment 5 to coat the roller surface of the abrasive roller 1 that enters the coating zone 100 with mixed abrasive. The mixed abrasive on the abrasive roller 1 forms an abrasive layer after being rolled by the abrasive pressure roller 2 in the granulation zone 200. During this process, the hydraulic pressure of the heat transfer fluid corresponding to the coating zone 100 and the granulation zone 200 is controlled to be less than or equal to a preset threshold so that the roller surfaces corresponding to the coating zone 100 and the granulation zone 200 remain flat.

[0045] In addition, after the mixed abrasive is sprayed on the coating equipment 5, the mixed abrasive can also be smoothed by scraping.

[0046] Specifically, a scraper 6 is also provided between the roller surface of the abrasive roller 2 and the roller surface of the abrasive roller 1. The step of forming an abrasive layer after the mixed abrasive on the abrasive roller 1 is rolled by the abrasive roller 2 in the granulation zone 200 includes: The mixed abrasive material entering the granulation zone 200 is scraped flat by a scraper 6. After the scraping treatment, the mixed abrasive material is then rolled by the abrasive roller 2 so that the abrasive groove 101 at the corresponding position is filled with mixed abrasive material to form an abrasive layer of a preset thickness.

[0047] The thickness of the abrasive layer can be adjusted by controlling the gap between the scraper 6 and the roller surface of the abrasive roller 1.

[0048] In one embodiment, before coating the roller surface of the abrasive roller 1 entering the coating zone 100 with the mixed abrasive, the following steps are further included: A release agent is sprayed onto the surface of the abrasive roller 1 that enters the coating zone 100.

[0049] The release agent can be silicone oil emulsion or polyvinyl alcohol solution, etc., and there are no restrictions here.

[0050] Specifically, the release agent is evenly applied to the surface of the abrasive roller 1 using an atomizing spraying device, forming a continuous protective film. When the mixed abrasive is applied to the surface of the abrasive roller 1, the release agent isolates the adhesive from direct contact with the roller surface, effectively reducing the adhesion strength between the cured abrasive layer and the roller surface. When the roller surface of the abrasive roller 1 subsequently undergoes elastic deformation, the lubricating effect of the release agent reduces the sliding resistance between the abrasive layer and the roller surface, allowing the abrasive layer to detach completely from the roller surface without structural tearing.

[0051] Furthermore, after the abrasive layer is formed by the abrasive roller 2 and before the primer is applied to the surface of the abrasive belt substrate 4, the following steps are also included: The heat-conducting fluid corresponding to the abrasive layer is heated and maintained at 60 ℃ for 1 minute to initially shape the abrasive layer.

[0052] Specifically, after the abrasive layer is formed by the abrasive roller 2, the heat-conducting liquid corresponding to the abrasive layer inside the abrasive roller 1 is heated to 60°C and maintained for 1 minute. The heat is conducted to the abrasive layer through the abrasive roller 1, causing the polymer chains in the adhesive of the abrasive layer to undergo a partial cross-linking reaction, thus achieving pre-curing treatment. This ensures that the abrasive layer maintains its preset geometric shape when transferred to the abrasive belt substrate 4, while avoiding a decrease in interfacial bonding force due to over-curing.

[0053] In the process of step 3, the hydraulic pressure of the heat transfer fluid corresponding to the coating zone 100 and the granulation zone 200 needs to be controlled to be less than or equal to a preset threshold so that the roller surface of the abrasive roller 1 corresponding to the coating zone 100 and the granulation zone 200 remains flat.

[0054] The preset threshold is the critical pressure value that causes the surface of the abrasive roller 1 to undergo elastic deformation.

[0055] When the hydraulic pressure is lower than or equal to the preset threshold, the pressure inside the cavity 102 is low, and the roller surface of the abrasive roller 1 maintains a rigid structure. That is, the roller surfaces corresponding to the coating area 100 and the granulation area 200 remain flat, ensuring accurate embedding of abrasive particles and stable formation of the abrasive layer.

[0056] Step 4: Apply primer to the surface of the abrasive belt substrate 4.

[0057] The primer is preferably a phenolic resin adhesive, which provides adhesion for the bonding of the abrasive layer and the abrasive belt substrate 4.

[0058] Specifically, the surface of the abrasive belt substrate 4 is first cleaned, and then a layer of phenolic resin adhesive is evenly coated on it.

[0059] Step 5: Drive the abrasive belt conveyor roller 3 to rotate in opposite directions with the abrasive roller 1. The abrasive belt conveyor roller 3 drives the abrasive belt substrate 4 to move in an axial direction perpendicular to the abrasive belt conveyor roller 3, so that the abrasive belt substrate 4 contacts the abrasive roller 1 in the demolding zone 300. At the same time, pressurize the heat-conducting liquid corresponding to the demolding zone 300 to a hydraulic pressure greater than a preset threshold, so that the roller surface corresponding to the demolding zone 300 undergoes elastic deformation, so that the abrasive layer is demolded from the abrasive roller 1 and the abrasive layer is tightly bonded to the abrasive belt substrate 4, thus obtaining a composite abrasive belt.

[0060] When the hydraulic pressure rises to a level exceeding a preset threshold, the pressure inside the cavity 102 will cause the roller surface of the abrasive roller 1 to undergo elastic deformation, reducing the contact area between the roller surface of the abrasive roller 1 and the abrasive layer, thus causing the abrasive layer to separate from the abrasive roller 1.

[0061] Furthermore, a cleaning zone 400 is provided between the coating area 100 and the demolding area 300 in terms of spatial location. The coating area 100, the granulation area 200, the demolding area 300, and the cleaning zone 400 are sequentially connected continuous areas. In some embodiments of the present invention, after step 5 above, the following step is further included: The surface of the abrasive roller 1 entering the cleaning zone 400 is cleaned. Repeat steps 3 through 5 of the preparation process described above.

[0062] This enables the continuous production of composite abrasive belts.

[0063] After the surface of the abrasive roller 1 is demolded, the surface of the roller in the cleaning area 400 can be cleaned with anhydrous ethanol. After the anhydrous ethanol evaporates quickly, the subsequent process can be carried out to achieve continuous preparation of composite abrasive belt.

[0064] Furthermore, after obtaining the composite abrasive belt, it can be dried and shaped, specifically including the following steps: The composite abrasive belt was dried at 70°C for 20 minutes and then dehumidified. The composite abrasive belt was dried again at 90℃ for 40 minutes to complete the shaping process.

[0065] Specifically, during initial drying at 70℃, free moisture in the adhesive is rapidly expelled through dehumidification, preventing moisture retention and the formation of internal pores. At this stage, the adhesive molecular chains begin to cross-link but are not fully hardened, forming a preliminary bonding interface between the abrasive grains and the substrate. When the temperature rises to 90℃, the active groups in the adhesive react more rapidly at high temperatures, promoting the formation of a three-dimensional network structure in the polymer chains, thus stabilizing the interfacial bonding strength between the abrasive grains and the substrate. Through the synergistic effect of staged temperature and humidity control, the curing rate of the abrasive layer from the surface to the interior tends to be uniform, avoiding the problems of excessively rapid surface hardening and internal stress concentration caused by single-stage high-temperature drying.

[0066] The above method effectively solves the problem of loose structure caused by improper temperature and humidity control during the drying process of abrasive layer. By controlling the temperature in stages, the cross-linking reaction of the adhesive is ensured to proceed fully. At the same time, the dehumidification treatment eliminates the negative impact of residual moisture on the interfacial bonding strength, and finally a composite abrasive belt with uniform and dense structure and stable bonding strength is obtained.

[0067] Please see Figure 4 and Figure 5 The present invention also provides a composite abrasive belt, which is manufactured by the above-described method for preparing composite abrasive belts. The composite abrasive belt includes a belt substrate 4 and an abrasive layer 7 disposed on the surface of the belt substrate 4. The abrasive layer 7 includes abrasive grains 8 and an adhesive 9. Grinding units 10 protruding along the surface of the belt substrate 4 are provided on the surface of the abrasive layer 7, and gaps are provided between adjacent grinding units 10.

[0068] The grinding unit 10 refers to a regularly arranged structure formed by a mold assembly. Specifically, its shape can be controlled by pre-set abrasive grooves on the surface of the abrasive roller, ensuring that the external dimensions and distribution position of each grinding unit 10 are consistent. The gap design between adjacent grinding units 10 allows chips to be discharged through the gaps during the grinding process, reducing the risk of clogging.

[0069] Each grinding unit 10 contains a large number of abrasive grains 8, achieving typical multi-layer grinding. During the grinding process, the cutting edges of multiple abrasive grains 8 work together to provide a stable grinding force. When the uppermost abrasive grain 8 becomes dull and fails due to grinding, the dulled abrasive grain 8 falls off due to increased grinding resistance and loss of adhesive 9. At this time, new abrasive grains 8 in the middle and lower layers are exposed and participate in grinding, thereby significantly improving grinding efficiency and effectively improving the surface quality of the workpiece. It has the significant characteristics of high-efficiency and high-quality grinding.

[0070] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for preparing a composite abrasive belt, characterized in that, Includes the following steps: Step 1: Mix the abrasive grains with the adhesive and let it stand to obtain the mixed abrasive. Step 2: Provide a mold assembly, including an abrasive roller, an abrasive pressure roller, and an abrasive belt conveyor roller arranged parallel to each other. The abrasive belt substrate is sandwiched between the abrasive roller and the abrasive belt conveyor roller. The abrasive pressure roller and the abrasive roller are arranged side by side along the plane of the abrasive belt substrate, and the roller surface of the abrasive pressure roller is positioned opposite the roller surface of the abrasive roller at a preset distance. The roller surface of the abrasive roller has a plurality of abrasive grooves arranged in a preset pattern. The interior of the abrasive roller has a plurality of circumferentially arranged and axially extending cavities, and each of the cavities is filled with a heat-conducting liquid. Spatially, the area corresponding to the abrasive roller and the coating equipment is the coating area, the area corresponding to the abrasive roller and the abrasive pressure roller is the granulation area, and the area corresponding to the abrasive roller and the abrasive belt substrate is the demolding area. The coating area, the granulation area, and the demolding area are continuous areas. Step 3: Drive the abrasive roller and the abrasive pressure roller to rotate in opposite directions. Use the coating equipment to coat the roller surface of the abrasive roller entering the coating zone with the mixed abrasive. The mixed abrasive on the abrasive roller forms an abrasive layer after being rolled by the abrasive pressure roller in the granulation zone. During this process, the hydraulic pressure of the heat-conducting fluid corresponding to the coating zone and the granulation zone is controlled to be less than or equal to a preset threshold so that the roller surface corresponding to the coating zone and the granulation zone remains flat. Step 4: Apply a primer to the surface of the abrasive belt substrate; Step 5: Drive the abrasive belt conveyor roller and the abrasive roller to rotate in opposite directions. The abrasive belt conveyor roller drives the abrasive belt substrate to move in an axial direction perpendicular to the abrasive belt conveyor roller, so that the abrasive belt substrate contacts the abrasive roller in the demolding zone. At the same time, pressurize the heat-conducting liquid corresponding to the demolding zone to a hydraulic pressure greater than the preset threshold, so that the roller surface corresponding to the demolding zone undergoes elastic deformation, so that the abrasive layer is demolded from the abrasive roller and the abrasive layer is tightly bonded to the abrasive belt substrate, thereby obtaining a composite abrasive belt.

2. The method for preparing composite abrasive belts according to claim 1, characterized in that, The preset threshold is the critical pressure value that causes the surface of the abrasive roller to undergo elastic deformation.

3. The method for preparing composite abrasive belts according to claim 1, characterized in that, A scraper is also provided between the roller surface of the abrasive pressure roller and the roller surface of the abrasive roller. The step of forming an abrasive layer by the mixed abrasive on the abrasive roller after being rolled by the abrasive pressure roller in the granulation zone includes: The mixed abrasive entering the grinding zone is leveled by a scraper. After leveling, the mixed abrasive is then rolled by the abrasive pressure roller so that the abrasive groove at the corresponding position is filled with the mixed abrasive, forming an abrasive layer of a preset thickness.

4. The method for preparing composite abrasive belts according to claim 1, characterized in that, Before coating the roller surface of the abrasive roller entering the coating zone with the mixed abrasive, the following steps are also included: A release agent is sprayed onto the surface of the abrasive roller that enters the coating zone.

5. The method for preparing composite abrasive belts according to claim 1, characterized in that, After the abrasive layer is formed by the abrasive roller and before the primer is applied to the surface of the abrasive belt substrate, the following steps are also included: The heat-conducting liquid corresponding to the abrasive layer is heated and maintained at 60°C for 1 minute to preliminarily shape the abrasive layer.

6. The method for preparing composite abrasive belts according to claim 1, characterized in that, A cleaning zone is also provided between the coating area and the demolding area in terms of spatial location. The coating area, the granulation area, the demolding area, and the cleaning zone are sequentially connected continuous areas. After step 5, the following steps are also included: The surface of the abrasive roller entering the cleaning zone is cleaned. Repeat steps 3 through 5.

7. The method for preparing composite abrasive belts according to claim 1 or 6, characterized in that, After obtaining the composite abrasive belt, the following steps are also included: The composite abrasive belt was dried at 70°C for 20 minutes and then dehumidified. The composite abrasive belt is dried again at 90°C for 40 minutes to complete the shaping process.

8. The method for preparing composite abrasive belts according to claim 1, characterized in that, The mixed abrasive is made by mixing the abrasive grains and the adhesive in a 1:3 ratio, and the adhesive is made by mixing polyurethane emulsion and phenolic resin in a 1:20 ratio.

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