Manufacturing method for polishing member

Abstract

To provide a manufacturing method for a polishing member that is excellent in environmental performance.SOLUTION: The manufacturing method for a polishing member comprises: a first applying step of applying powder resin to a base material; a second applying step of applying polishing particles toward the powder resin on the base material; a third applying step of re-applying the powder resin toward the polishing particles on the base material; and a heating step of heating the base material so that powder resin is melted and the polishing particles are fixed to the base material.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a polishing member. [Background technology]

[0002] Many methods for manufacturing abrasive members have been proposed (see, for example, Patent Documents 1 and 2). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 05-253851 [Patent Document 2] Japanese Patent Application Laid-Open No. 2005-144628 Summary of the Invention [Problem to be solved by the invention]

[0004] For example, abrasive members are manufactured by coating a substrate with a binder resin and then attaching abrasive particles to the binder resin. Organic solvents are used in this type of binder resin. These organic solvents have a significant environmental impact because they are released into the atmosphere during the manufacturing process.

[0005] SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a method for producing an abrasive member that is environmentally friendly. [Means for solving the problem]

[0006] The above object can be achieved by a method for manufacturing an abrasive member, comprising: a first application step of applying powder resin to a substrate; a second application step of applying abrasive particles toward the powder resin on the substrate; a third application step of applying the powder resin again toward the abrasive particles on the substrate; and a heating step of heating the substrate so that the powder resin melts and the abrasive particles are fixed to the substrate.

[0007] The heating step may be carried out during the first, second, and third coating steps.

[0008] The heating step may heat the substrate using a heating element heated by induction heating.

[0009] The first coating step, the second coating step, and the third coating step may be performed at locations separate from each other.

[0010] At least one of the first, second and third application steps may be an application step using static electricity or compressed air.

[0011] The substrate may be a sheet, a film, or a continuous strip-shaped member.

[0012] The powder resin may be thermosetting and contain at least one of epoxy-based, epoxy polyester-based, polyester-based, acrylic-based, and fluororesin-based powders.

[0013] The powder resin may be thermoplastic and may contain powder of at least one of vinyl chloride, polyethylene, and nylon.

[0014] The powder resin may be thermoplastic and may include powder of an engineering plastic.

[0015] The engineering plastic may be PPS, PEEK, or PI.

[0016] The substrate may be any one of a plastic film, paper, nonwoven fabric, woven fabric, and metal plate.

[0017] The metal plate may be stainless steel. [Effects of the Invention]

[0018] According to the present invention, it is possible to provide an environmentally friendly method for producing a polishing member. [Brief explanation of the drawings]

[0019] [Figure 1] 3A to 3C are explanatory diagrams of a method for manufacturing a polishing member. DETAILED DESCRIPTION OF THE INVENTION

[0020] FIG. 1 is an explanatory diagram of the manufacturing method of the polishing member of this embodiment. The substrate W is wound into a roll. One end of the substrate W is transported to the right in FIG. 1 by a roller or the like (not shown). The coating devices 10, 20, and 30 are installed so as to face the substrate W in order in the transport direction of the substrate W. The coating devices 10, 20, and 30 are arranged at predetermined intervals from each other in the transport direction of the substrate W. The heating device 40 is installed so as to face the substrate W across the area where the coating devices 10, 20, and 30 are installed.

[0021] The coating device 10 applies powder resin to the upper surface of the substrate W. The process performed by the coating device 10 is a so-called undercoating process, which corresponds to the first coating process. Next, the coating device 20 applies abrasive particles to the surface of the substrate W that has been coated with the powder resin. The process performed by the coating device 20 corresponds to the second coating process. Next, the coating device 30 applies powder resin again to the surface of the substrate W that has been coated with the abrasive particles. The process performed by the coating device 30 is a so-called topcoating process, which corresponds to the third coating process. Note that the specific coating method of the coating devices 10, 20, and 30 may be a coating method using compressed air, or may be electrostatic coating using, for example, an electrostatic gun.

[0022] During the application process, the substrate W is heated by the heating device 40. The heating device 40 includes a coil through which an alternating current flows and a conductive heating element that generates heat when an induced current flows when electricity is applied to the coil. The substrate W is heated by the heat from this heating element. The process performed by the heating device 40 corresponds to the heating process. This melts the powder resin sprayed onto the substrate W from the application devices 10 and 30. As a result, when the substrate W separates from the heating device 40, the substrate W cools and the powder resin on the substrate W solidifies. The abrasive particles applied to the substrate W in this way are fixed to the substrate W. The substrate W is then cut to the desired size to produce a sheet-like abrasive member.

[0023] As described above, this manufacturing method is environmentally friendly because it does not use organic solvents. Furthermore, compared to when organic solvents are used, when powder resins are used, maintenance and management are easier. Therefore, the manufacturing of abrasive members using this manufacturing method can be carried out unmanned.

[0024] As described above, the powder resin is applied to the substrate W before the abrasive particles are applied, and then the powder resin is again applied to the substrate W after the abrasive particles are applied. This improves the adhesion of the abrasive particles. In addition, the substrate W is heated while the powder resin and abrasive particles are being applied to the substrate W. This shortens the manufacturing time.

[0025] The applicators 10, 20, and 30 are spaced apart from one another. Therefore, even if, for example, the powdered resin sprayed from the applicator 10 or 30 falls off the substrate W, and the abrasive particles sprayed from the applicator 20 fall off the substrate W, the powdered resin and the abrasive particles are prevented from mixing around the applicators 10, 20, and 30. As a result, it is easy to collect the powdered resin and the abrasive particles separately. The collected powdered resin and the abrasive particles can be reused. In this way, the material reuse rate is improved.

[0026] The powder resins used in the first and third coating steps may be the same or different types, and the amounts of the powder resins applied in the first and third coating steps may be the same or different.

[0027] The powder of the powder resin may be thermosetting or thermoplastic. Thermosetting powders include epoxy-based powder resins, polyester-based powder resins, epoxy-polyester-based powder resins, fluororesin-based powder resins, and acrylic-based powder resins. Thermoplastic powders include vinyl chloride, polyethylene, nylon, and the like.

[0028] The shape of the substrate is not limited, and may be a sheet, film, or strip. The substrate may also be a plastic film, paper, nonwoven fabric, woven fabric, or metal. Commercially available alumina (Al2O3), silica (SiO2), silicon carbide (SiC), diamond, cubic boron nitride (cBN), and the like can be used as abrasive particles. Abrasive particles of various particle sizes can be selected to suit the object to be polished.

[0029] Although the embodiments of the present invention have been described in detail above, the present invention is not limited to such specific embodiments, and various modifications and variations are possible within the scope of the gist of the present invention as defined in the claims. [Explanation of symbols]

[0030] W Base material 10, 20, 30 Coating equipment 40 Heating device

Claims

1. a first application step of applying a powder resin to a substrate; a second application step of applying abrasive particles toward the powder resin on the base material; a third application step of applying the powder resin again toward the abrasive particles on the base material; a heating step of heating the substrate so that the powder resin melts and the abrasive particles are fixed to the substrate; A method for manufacturing a polishing member comprising:

2. 2. The method for manufacturing an abrasive member according to claim 1, wherein the heating step is carried out during the first, second, and third coating steps.

3. The method for manufacturing a polishing member according to claim 2 , wherein the heating step heats the substrate using a heating element heated by induction heating.

4. 4. The method for manufacturing an abrasive member according to claim 3, wherein the first coating step, the second coating step, and the third coating step are carried out at locations separate from each other.

5. 5. The method for manufacturing an abrasive member according to claim 1, wherein at least one of the first, second and third coating steps is a coating step using static electricity or compressed air.

6. 5. The method for manufacturing an abrasive member according to claim 1, wherein the substrate is a sheet, a film, or a continuous strip-shaped member.

7. 5. The method for manufacturing an abrasive member according to claim 1, wherein the powder resin is thermosetting and contains at least one of epoxy-based, epoxy polyester-based, polyester-based, acrylic-based, and fluororesin-based powders.

8. 5. The method for manufacturing an abrasive member according to claim 1, wherein the powdered resin is thermoplastic and contains at least one powder of vinyl chloride, polyethylene, or nylon.

9. 5. The method for manufacturing an abrasive member according to claim 1, wherein the powdered resin is thermoplastic and contains powder of engineering plastic.

10. The method for manufacturing an abrasive member according to claim 9, wherein the engineering plastic is PPS, PEEK, or PI.

11. 5. The method for manufacturing an abrasive member according to claim 1, wherein the substrate is any one of a plastic film, paper, nonwoven fabric, woven fabric, and metal plate.

12. The method for manufacturing an abrasive member according to claim 11, wherein the metal plate is made of stainless steel.

Images