• 专利附录
  • 专利说明
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    • 专利摘要:
    ABRASIVE SAND AND METHOD FOR ABRASION OF GLASS, CERAMIC AND METALLIC MATERIALS. The present invention relates to an abrasive sandpaper used to abrasion the surfaces of glass, ceramic and metallic materials, the abrasive sandpaper being provided with a substrate layer and an abrasive layer provided on a first surface side of the layer of substrate and including an abrasive material, and the abrasive layer having a plurality of mutually separated base portions in the substrate layer, column or trunk shaped tip portions arranged mutually apart in the base portions, and a group of grooves containing a plurality of groove portions provided between the base portions, so that the substrate layer is exposed, with each of the grooves intercepting each other.
    公开号:BR112015000772B1
    申请号:R112015000772-4
    申请日:2013-07-08
    公开日:2021-01-19
    发明作者:Toru Aoki；Akira Yoda；Takayuki Tachihara
    申请人:3M Innovative Properties Company；
    IPC主号:
    专利说明:

    Background
    [001] The present invention relates to an abrasive sandpaper and a method for abrasion of glass, ceramic and metallic materials.
    [002] Conventional abrasive files include, for example, an abrasive component, as described in PCT application No. 2002-542057. The abrasion component thereof is configured as supplied with a backing material that has an abrasive material on one surface. The shape of the abrasive material can, for example, be a cube, a block shape, cylindrical, rectangular, or the like. In addition, with an abrasive component described in the specification of the unexamined US patent application publication No. US 2011/0053460, a conical protuberance is formed in a base portion of an abrasive layer formed from an abrasive material. An objective of this protuberance is to simplify the initial covering (an operation performed to obtain a flat abrasive surface), and to determine when the covering is complete (when the abrasive surface becomes flat). When trimming the lump through the cover to create leveling, a base portion that has a uniform abrasive material can be used to implement abrasion.
    [003] When abrasive glass reinforced with metal wire, heat resistant glass, or other vitreous substrate for industrial use, or when abrasing a large substrate containing a ceramic or metallic material, extending the life of an abrasive sandpaper is essential . A conceivable measure to extend the life of an abrasive sandpaper is to increase the height of the protruding portion of the abrasive layer to increase the volume. However, when the height of the lump portion is simply increased, in some cases the lump portion can easily fall apart. Therefore, connecting a root portion of the lump portion to the abrasive layer is also conceivable. However, also with this configuration, preventive measures are necessary to deal with a decrease in the leveling of the abrasive layer due to the contraction when the resin is cured by light, and with a decrease in flexibility due to the integration of the abrasive layer. Summary of the invention
    [004] One aspect of the present invention is an abrasive sandpaper used to make abrasion on surfaces of glass, ceramic and metallic materials, the abrasive sandpaper being provided with a substrate layer and an abrasive layer provided on a first surface side of the substrate layer and including an abrasive material, and the abrasive layer having a plurality of mutually separated base portions in the substrate layer, column or trunk shaped tip portions arranged mutually apart in the base portions, and a group of grooves including a plurality of groove portions provided between the base portions, so that the substrate layer is exposed between the base portions, with each of the grooves intercepting each other.
    [005] Additionally, an aspect of the present invention is a method for abrasion of glass, ceramic and metallic materials using the abrasive sandpaper above. The method includes a process of bonding a second surface side of the substrate layer to an abrasion disc, placing the abrasive layer and the abrasive object in contact with each other, and then rubbing with the abrasive sandpaper and an abrasive fluid. sanding against the abrasive object, at the same time as the sanding fluid is introduced between the abrasion object and the abrasive layer.
    [006] According to the present invention, a longer service life of the abrasive sandpaper can be achieved, and the leveling and flexibility of the abrasive layer can be ensured. Brief description of the drawings
    [007] Figure 1 is a perspective view showing an abrasive sandpaper in accordance with an embodiment of the present invention.
    [008] Figure 2 is an enlarged perspective view showing the main parts of the abrasive paper illustrated in Figure 1.
    [009] Figure 3 is an enlarged side view showing the main parts of the abrasive paper illustrated in Figure 1.
    [010] Figures 4a and 4b are side views showing a variation of the base portion.
    [011] Figures 5a to 5e are contour views showing examples of groups of grooves formed between the base portions.
    [012] Figure 6 is a side view showing a variation of a groove portion between the tip portions.
    [013] Figures 7a and 7b are side views showing a method for abrasion of an object that will undergo abrasion with the use of the abrasive paper illustrated in Figure 1.
    [014] Figures 8a to 8c are illustrations showing schematically the functional effects of abrasive sandpaper.
    [015] Figures 9a to 9e are side views showing abrasive sandpaper sample formats according to comparative modalities and examples.
    [016] Figure 10 is an illustration showing the results of a test to confirm the benefits. Detailed Description
    [017] Preferred modalities of an abrasive sandpaper and a method for abrasion of glass, ceramic and metallic materials according to the present invention are described in detail below, with reference to the figures.
    [018] Figure 1 is a perspective view showing an abrasive sandpaper according to an embodiment of the present invention. Additionally, Figure 2 is an enlarged perspective view showing the main parts of the abrasive paper shown in Figure 1, and Figure 3 is an enlarged side view of it. As shown in Figures 1 to 3, an abrasive sandpaper 1 is configured as shown with a substrate layer 11 that serves as a support element for the sandpaper, and an abrasive layer 12 containing an abrasive material. Abrasive sandpaper 1 is an abrasive sandpaper that is used to abrasion glass reinforced with metal wire, heat resistant glass, or another vitreous substrate for industrial use, or abrasion a large substrate containing a ceramic or metallic material . Abrasive sandpaper 1, for example, generally forms a disc shape with a diameter of about 10 mm to 2500 mm.
    [019] The substrate layer 11, for example, is configured with a thickness of about 1 mm from polymeric film, paper, vulcanized fiber, treated non-woven material, treated woven material, or the like, so that the sandpaper abrasive 1 has a certain amount of strength and flexibility. Of these materials, the use of polymeric film is preferred. Examples of polymeric film include polyethylene terephthalate film, polyester film, copolyester film, polyimide film, polyamide film, and the like.
    [020] The abrasive layer 12, for example, is configured including a binder, abrasive particles, and a filler, and is formed on a surface of the substrate layer 11. In addition, the abrasive layer 12 can also contain several components as a coupling agent, a precipitation inhibitor, a hardening agent (initiator), and a photosensitizer.
    [021] binder is formed from a binder precursor. The binder precursor contains a resin in an uncured or unpolymerized state, and when the abrasive layer 12 is manufactured, the resin in the binder precursor is polymerized or cured, forming a binder. The binder precursor uses a condensation-curable resin, an addition-curable resin, a free radical-curable resin, or a combination thereof.
    [022] Abrasive particles are diamond microsphere abrasive particles, for example. The abrasive particles of diamond microspheres used here, for example, are abrasive particles containing approximately 6% to 65% by volume of abrasive diamond particles that have a diameter of 25 microns or less and are dispersed in a continuous matrix. of non-fused, microporous metal oxide of approximately 35% to 94% by volume. The metal oxide matrix has a Knoop hardness value of approximately less than 1,000, and contains at least one metal oxide selected from a group that includes zirconium oxide, silicon oxide, aluminum oxide, magnesium oxide and titanium oxide.
    [023] The amount of abrasive diamond microsphere particles contained in the abrasive layer 12 is generally approximately 1% by weight, or more, and is preferably approximately 2% by weight, or more. In addition, the amount of diamond microsphere abrasive particles contained in the abrasive layer 12 is more preferably approximately 5% by weight, or more, and most preferably approximately 7% by weight, or more. The amount of diamond microsphere abrasive particles contained in the abrasive layer 12 is generally approximately 30% by weight, or less, and is preferably approximately 25% by weight, or less. In addition, the amount of diamond microsphere abrasive particles contained in the abrasive layer 12 is more preferably approximately 15% by weight, or less, and most preferably approximately 13% by weight, or less.
    [024] In the formation of the abrasive layer 12, the diamond abrasive particles are mixed with a metallic oxide or an aqueous solution of an oxide precursor, and the obtained aqueous paste is added to a dehydrated liquid (for example, 2-ethyl- 1-hexanol) that was stirred. The water is then removed from the aqueous dispersion paste, and the aqueous paste is then filtered, dried, and heated to obtain abrasive layer 12. The abrasive diamond microsphere particles in abrasive layer 12 are generally spherical in shape, and are at least twice the size compared to the original diamond particles used to make abrasive particles.
    [025] The filler is a material that is used to control the erosion rate of the abrasive layer 12. The filler is a particulate material that has an average particle size of generically 0.01 to 100 μm, and typically 0, 1 to 40 μm, for example. Controlling the rate of erosion of the abrasive layer 12 during abrasion is important to achieve a balance between the rate of abrasion and the service life. If the load load is too high, the abrasive layer 12 can wear out very quickly, thus resulting in an insufficient abrasion operation. Conversely, if the loading load is too low, the abrasive layer 12 can wear out very slowly, thus allowing the abrasive particles to become blind, resulting in a decrease in the abrasion rate.
    [026] The amount of filler contained in abrasive layer 12 is generally approximately 40% by weight, or more, more preferably approximately 45% by weight, or more, and most preferably 50% by weight, or more. In addition, the amount of filler contained in the abrasive layer 12 is generally approximately 60% by weight, or less.
    [027] Examples of fillers include metal carbonates (such as calcium carbonate (chalk, calcite, peat, travertine, marble, and limestone), calcium and magnesium carbonate, sodium carbonate, magnesium carbonate, and the like), silica ( such as crystal, glass microspheres, glass bubbles, glass fibers, and the like), silicates (such as talc, clays (montmorillonite), feldspar, mica, calcium silicate, calcium metasilicate, sodium aluminosilicate, sodium silicate, lithium silicate , potassium silicate, and the like), metal sulphates (such as calcium sulphate, barium sulphate, sodium sulphate, aluminum sodium sulphate, aluminum sulphate, and the like), natural plaster, vermiculite, wood powder, aluminum hydrate, carbon black, metal oxides (such as calcium oxide (lime), aluminum oxide, tin oxide (for example, stanic oxide), titanium dioxide, and the like), and metal sulfites (calcium sulfite and the like), thermoplastic particles (polycarbonate, poly imide, polyester, polymethylene, polysulfone, polystyrene, acrylonitrile-butadiene-styrene block copolymer, polypropylene, acetal polymers, polyurethane, nylon particles), and thermoset particles (such as phenolic bubbles, phenolic microspheres, polyurethane foam particles , and the like), and the like.
    [028] The filler can also be a salt as a halide salt. Examples of halide salts include sodium chloride, potassium cryolite, sodium cryolite, ammonium cryolite, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluorides, potassium chloride, and magnesium chloride. Examples of metal fillers include tin, lead, bismuth, cobalt, antimony, cadmium, iron and titanium. Examples of other fillers include sulfur, organic sulfur compounds, graphite, and metal sulfides.
    [029] Next, a structure of the abrasive layer 12 mentioned above is described.
    [030] The abrasive layer 12 has a tile structure like those shown in Figures 2 and 3. More specifically, the tile structure of the abrasive layer 12 has a plurality of base portions 13 arranged mutually apart in the substrate layer 11, and a plurality of tip portions 14 arranged mutually apart in the base portions 13.
    [031] The base 13 portions are arranged in a matrix format on the substrate 11, so that the density is from 0.01 to 80 base 13 portions per 1 cm2, for example. Each base portion 13 has a flat shape, approximately cuboid, with a thickness of 0.5 mm to 2.0 mm, for example, and an approximately square shape from a planar view. The base portion 13 is a rigid body, and if the thickness of the base portion 13 is too thick, there is a risk that the base portion 13 is easily affected by contraction. On the other hand, if the thickness of the base portion 13 is very thin, the abrasive layer 12 can crack more easily. The thickness range above is favorable because in this range, the resistance of the base portion 13 can be ensured, and the impact of the contraction is eliminated.
    [032] A surface area of a top face 30 (surface forming a tip portion 14) of the base portion 13 is generally 30 mm2 or more, preferably 50 mm2 or more, and more preferably 100 mm2 or more, for a case in which an oblong glass measuring 3 mx 4 m suffers abrasion, for example. In addition, the surface area of the top face 30 of the base portion 13 is generally 400 mm2 or less, preferably 300 mm2 or less, and more preferably 200 mm2 or less. Naturally, the optimum range differs depending on the object for abrasion and the machining pressure (the average sanding pressure is approximately 4.9 to 29.4 kPa (from 50 to 300 g / cm2), for example).
    [033] When selecting a band like this, a sufficient number of tip portions 14 can be arranged in the base portion 13, and an abrasion region can be ensured completely. In addition, from a similar point of view as in the case of thickness, if the surface area of the base portion 13 is very large, there is a concern that the flexibility of the substrate layer 11 may be lost. On the other hand, if the surface area of the base portion 13 is very small, the abrasive layer 12 becomes narrow, which could cause a decrease in the applicability of the abrasion. Consequently, within the above surface area ranges, both the applicability of abrasion and the flexibility of the substrate layer 11 can be ensured.
    [034] flat shape of the top face 30 of the base portion 13 can be suitably selected from polygons such as triangles, rectangles, hexagons, and the like, circular shapes including ellipse shapes, and the like. In the selection of this flat shape, consideration is given to the contact of the abrasive sandpaper 1 with the abrasive object accompanying mutual rotating movement, or rotating movement of only one of them, when abrasion is implemented, and a format that allows isotropic abrasion to be carried out is preferential. From this point of view, a circular, square, or other isotropic shape is more preferred than an oblong shape or other anisotropic shape for the flat shape of the top face 30 of the base portion 13. Additionally, by providing isotropy to the shape plane of the top face 30 of the base portion 13, isotropy can be allowed in the arrangement of the tip portions 14, and the tip portions 14 can be arranged at a high density in the base portion 13.
    [035] three-dimensional shape of the base portion 13 may also be a column-shaped body or a trunk-shaped body. In particular, a base portion 13 that has a trunk shape is preferred as tension is not easily concentrated in angular parts, and the surface area of contact with the substrate layer 11 is increased.
    [036] Here, the selection of the surface area of the base portion 13 will be described for a case where the base portion 13 is arranged in a square shape, as an example. To simplify the description, the contribution of a two-dimensional surface to a magnitude relation is replaced with the contribution of a one-dimensional width to the magnitude relation and explained. In the selection of a width dimension of the base portion 13, the extent of the undulation of the object's surface for abrasion, the extent of the resistance of the object's material for abrasion, the shape and external dimensions of the object for abrasion, the height of the portions of the object. tip 14, and the like must be considered. An interval of the surface ripple of the object for abrasion reaches about 1 μm for small objects, and about 1 m for large objects. Consequently, for example, by combining the width of the corrugation gap and the width of the base portion 13, the abrasive surface can come in closer contact with the surface of the object for abrasion. Additionally, if the abrasion object is formed from a material that does not easily deform, the surface ripple does not change easily during abrasion, and therefore decreasing the width of the base portion 13 makes it easier than the abrasive surface comes in close contact with the surface of the object for abrasion. On the other hand, if the abrasion object is formed from a material that deforms easily, the surface ripple changes easily during abrasion, and therefore, increasing the width of the base portion 13 makes it easier to make the abrasive surface to come in close contact with the surface of the object for abrasion.
    [037] Additionally, a small abrasion object has a diameter of about 20 mm, for example, and a large abrasion object reaches up to about 3 mx 3 m, for example, and therefore, the selection of the width of the base 13 according to these dimensions is preferred. In relation to the tip 14, when an aspect ratio of the tip 14 is high, the torque at the tip 14 (moment of force around the root of the base portion 13) during abrasion becomes large, and therefore, it is preferable to fasten fully the width of the base portion 13 and retain the tip 14.
    [038] Adjacent base portions 13 are partitioned by the groove portions 15 which are provided at a prescribed spacing on the substrate layer 11. For example, as shown in Figure 3, the bottom portion of the groove portions 15 is a shape in R (round shape) with a radius of 0.8 mm over the substrate layer 11, so that the substrate layer 11 is exposed at the apex portion of the bottom portion. It should be noted that "exposure" of the substrate 11, as mentioned here, means that a thickness of the abrasive material in the bottom portion of the groove portions 15 that essentially does not obstruct the flexibility of the substrate layer 11 is desired, and the layer of substrate 11 need not necessarily be completely exposed in the bottom portion of the groove portions 15.
    [039] When this type of groove portion 15 is formed, the lateral surfaces of the base portion 13 have a root portion that takes on a tapered shape. If the abrasive object with abrasive sandpaper 1 is a large substrate, a large load tends to be applied to abrasive sandpaper 1, resulting from the rigidity of the abrasive object. Therefore, a joint force in relation to the substrate layer 11, and a configuration that relieves the added stress during abrasion are required in the abrasive layer 12. Therefore, when adopting a tapered shape for the lateral surface portions in the base portion 13 , the surface contact area between the substrate layer 11 and the base portion 13 can be maintained, and joint strength in relation to the substrate layer 11 can be ensured. In addition, due to the fact that the root portion of the base portion 13 does not form a notch, the stress added to the root portion of the base portion 13 during abrasion can be relieved.
    [040] In addition to the round shape shown in Figure 3, the tapered shape of the base portion 13 may also, for example, have side surfaces that are entirely sloping surfaces, such as a base portion 13A shown in Figure 4a, and may have a surface shape (including a beveled surface shape) in which only the root portions of the side surfaces are inclined surfaces, such as a base portion 13B shown in Figure 4b. Also with these types of shapes, the surface contact area between the substrate layer 11 and the base portion 13 can be completely maintained, and joint strength between the substrate layer 11 and the base portion 13 can be ensured. Additionally, due to the fact that the root portion of the base portion 13 does not form a notch, concentration of stresses located in the root portion of the base portion 13 can be avoided.
    [041] The width of the groove portions 15 can be appropriately selected, for example, in the range of approximately 0.5 mm to 3 mm. If the width of the groove portions 15 is too narrow, there is a concern that the flexibility of the substrate layer 11 may decrease. In addition, it is also conceivable that fragments of abrasion, which are generated during abrasion of an object to be abrased, could easily clog the groove portions 15, resulting in a decrease in abrasion efficiency. On the other hand, if the width of the groove portions 15 is very wide, the volume per unit of surface area of the tip portions 14 disposed in the base portion 13 will become small, and the service life of the abrasive sandpaper 1 will decrease. Consequently, by establishing the width of the groove portions 15 within the above range, the abrasion efficiency of the abrasive sandpaper 1 can be maintained and the service life of the same can be ensured.
    [042] These groove portions 15 are arranged between adjacent base portions 13, and form a group of grooves on the substrate layer 11. The requirements for the shape of the groove group include, for example, that the groove portions themselves 15 communicate with each other, and that mutually intercepting groove portions 15 are present.
    [043] Figures 5a to 5e show examples of groove group shapes between base portions 13 and 14. In this figure, groove portions 15 are represented by lines for convenience of description. As shown in Figure 5a, a groove group 17A is given as an example of a groove group configuration, where the straight line groove portions 15 are arranged in a lattice shape. The groove group 17A forms a square lattice in which the horizontal and vertical groove portions 15 are orthogonal. This configuration is superior because the abrasion isotropy is maintained even when there is a mutual rotating movement attached to the abrasive sandpaper 1 and the object for abrasion, or rotating movement of only one of them when the abrasion is implemented. The intercept angles of the groove portions 15 can be approximately 45 ° to 135 °, similar to the group of grooves 17B shown in Figure 5b. In this case too, a certain amount of abrasion isotropy can be maintained.
    [044] Additionally, the lines of the groove portions 15 are not limited to straight lines, and as shown in Figure 5c, a group of grooves 17C can also be formed by portions of groove 15 in the form of wavy lines arranged in a square grid. . In addition, as shown in Figure 5d, a group of grooves 17D can also be formed with lines extending radially from the center through lines of concentric shape, and a group of grooves 17E can be formed with lines extending radially to from the center through spiral lines. By forming a group of grooves 17 like those described above, fragments of abrasion generated during abrasion can flow smoothly through the groove portions 15, and decreases in abrasion efficiency due to the abrasion fragments obstructing the groove portions 15 can be suppressed.
    [045] The tip portions 14 are arranged in the base portion 13 so that the density ranges from 0.05 to 300 tip portions 14 per 1 cm2, for example. In this embodiment, the tip portions 14 form a prism of approximately quadrangular shape with a height of the substrate layer 11 of about 3 mm, and are formatted in a matrix format of 2x2 in the base portion 13, for example. In other words, this type of configuration means that respective groups are formed by a plurality of tip portions 14 sharing a single base portion 13. From a planar view, the top face (abrasive surface) of the tip portions 14 it forms, for example, an approximately square shape measuring 3 mm x 3 mm. The lateral surfaces of the tip 14 can also form a tapered shape at the same angle as the tapered shape of the base portion 13, for example.
    [046] The number of tip portions 14 formed in the base portion 13 can vary accordingly considering the following points. When the number of tip portions 14 is low, the abrasive surface and the abrasion object can easily come into contact at one or multiple points, due to the undulation of the surface of the abrasion object. Therefore, conforming to the roughness of the object's surface for abrasion tends to be easy. On the other hand, if the number of tip portions 14 is numerous, even if there is a ripple on the surface of the object for abrasion, the base portion 13 and the tip portions 14 follow the shape of the surface of the object for abrasion due to the flexibility of the substrate layer 11, and the abrasive surface and abrasion object can easily come into contact with each other at multiple points. Consequently, the amount of abrasion and the speed of abrasion increase, and the degree of finish tends to increase.
    [047] Additionally, adjacent tip portions 14 are partitioned by the groove portions 16. As shown in Figures 2 and 3, the bottom portion of the groove portions 16 form a round shape with a radius of about 0.8 mm in the base portion 13, so that the base portion 13 is exposed at the apex portion of the bottom portion. By adopting the rounded shape for the bottom portion of the groove portions 16 in this way, the base portion of the side surfaces of the tip 14 has a tapered shape. Consequently, the surface area of the connection between the tip portions 14 and the base portion 13 is ensured, and the collapse resistance of the tip portions 14 when the height of the tip portions 14 is increased can be increased more safely. Due to the fact that the volume of the abrasive layer 12 can be completely ensured by increasing the height of the tip portions 14, the service life of the abrasive sandpaper 1 can be further extended.
    [048] Note that the shape of the tip 14 can be a column-shaped body or a trunk-shaped body, and, for example, it can have a prism shape, a cylindrical shape, an elliptical cylinder shape, a truncated pyramid shape, a truncated circular cone shape, a truncated oval cone shape, or the like. When the tip portions 14 have a trunk shape, similar to the case of the base portion 13, tension is not easily concentrated in the angular parts, and the contact of the surface area with the base portion 13 is increased. As a result, resistance to collapse can be more fully maintained.
    [049] Additionally, the shape of the bottom portion of the groove portions 16 is not limited to a rounded shape. For example, similar to the groove portion 16A shown in Figure 6, the bottom portion of the groove portion 16 may also have a surface shape (including a chamfered shape) in which only the root portions of the side surfaces of the tip 14 are inclined surfaces. Also in this type of configuration, the root portion of the lateral surface of the tip 14 has a tapered shape. Consequently, even if the height of the tip portions 14 is increased, the collapse resistance of the tip portions 14 can be increased more safely.
    [050] Additionally, the aspect ratio of each of the tip portions 14 ranges from 0.2 to 10. In this range, an extension of the abrasive sandpaper 1 life can be achieved, and the resistance to the collapse of the tip portions 14 can be completely ensured. When the aspect ratio is reduced, the torque applied to the tip portions 14 during abrasion decreases, and the collapse resistance of the tip portions 14 can be better assured. On the other hand, when the aspect ratio is increased, the volume of the tip portions 14 can be completely ensured, and the service life of the abrasive sandpaper 1 can be further extended. Additionally, due to the fact that the height of the groove portions 16 increases, the sanding fluid can flow smoothly through the groove portions 16, and obstruction of the groove portions 16 by fragments of abrasion remaining accumulated in them can be avoided.
    [051] As a method for forming an abrasive layer 12 like the one above, a transfer method can be used, for example. In the transfer method, for example, a mold to which the tile structure above was applied is placed on an abrasion disc, and then a transfer mold is manufactured. This transfer mold is then filled with an aqueous diamond paste of the curing type, and a film that becomes the substrate layer 11 is laminated and fixed to the aqueous paste. Then, the aqueous paste is cured by optical irradiation, and when the film is detached from the transfer mold, an abrasive sandpaper 1 having an abrasive layer 12 formed on the substrate layer 11 is obtained. The formation of the abrasive layer 12 is not limited to the transfer method, and can be implemented through machining, embossing by cylinders, or the like.
    [052] Figures 7a and 7b are illustrations showing an abrasion method using abrasive sandpaper 1. Figure 7a is an example of surface abrasion, and an abrasion object P1 is glass reinforced with metal wire or a ceramic substrate, for example. In this example, the abrasive sandpaper 1 is attached to the surface of an abrasive disc 22 with an elastic structural layer 21 disposed between them, the abrasive disc 22 is rotated while providing a sanding fluid between the abrasive object P1 and the sandpaper abrasive 1, and the surface of the abrasive object P1 is abraded while a load is applied. A retainer 23 that secures the abrasion object P1 can also be rotated in the same direction as the abrasive wheel 22 or in an opposite direction of the same.
    [053] Additionally, Figure 7b is an example of double surface abrasion, and an object for P2 abrasion, which is the target of the abrasion, is a large glassy substrate or a metal plate, for example. In this example, respective abrasive files 1 are attached to the surfaces of the top and bottom abrasive discs 24 with a layer 21 that has interposed flexibility between each abrasive file 1 and abrasion disc 24, and an abrasion object P2 that is attached by a retainer 25 is placed between the abrasive discs 24. The abrasive discs 24 are rotated while providing sanding fluid between the abrasive object P2 and the abrasive files 1, and both surfaces of the abrasive object P2 are abraded while a load is applied. At this time, rotation of the abrasive discs 24 in opposite directions is preferred.
    [054] In the examples above, the attachment of abrasive files 1 to abrasion discs 22 and 24 can be done using, for example, a pressure sensitive adhesive. Examples of this type of adhesive include latex crepe, rosin, polyacrylate ester, acrylic polymer, polybutyl acrylate, vinyl ethers (for example, n-butyl polyvinyl ether), alkyl adhesives, rubber adhesives (for example, natural rubber, synthetic rubber, and chlorinated rubber), and mixtures thereof.
    [055] Additionally, examples of materials that can be used as layer 21 that has flexibility include polyurethane foam, rubber, elastomer, rubber foam, and the like. By interdisposing this type of layer 21, the ability to trace the shape of the abrasive sandpaper 1 in relation to the abrasive discs 22 and 24 can be improved. Note that the layer 21 that has flexibility can also be provided first on the second surface side (opposite the surface side of the abrasive layer 12) of the substrate layer 11 in the abrasive sandpaper 1. Additionally, the layer 21 that has flexibility does not it necessarily needs to be supplied, and the abrasive sandpaper 1 can be directly attached to the abrasive discs 22 and 24.
    [056] Examples of sanding fluids include water-based solutions containing one or more types of the following: amines, mineral oil, kerosene, mineral turpentine, water-soluble emulsions, polyethyleneimine, ethylene glycol, monoethanolaminea, diethanol amine, triethanolamine, propylene glycol , amine borate, boric acid, amine carboxylate, pine oil, indole, thioamine salt, amides, hexahydro-1,3,5-triethyl triazine, carboxylic acid, sodium 2-mercaptobenzothiazole, isopropanolamine, triethyl acid diamine tetra- acetic acid, propylene glycol methyl ether, benzotriazole, sodium-2-pyridinathiol-1-oxide, and hexylene glycol. The sanding fluid may also contain corrosion inhibitors, bactericides, stabilizers, surfactants, emulsifiers, or the like.
    [057] When this type of abrasion object P undergoes abrasion, as described above, with abrasive sandpaper 1, the abrasive layer 12 has base portions 13 arranged mutually apart on the substrate layer 11, and tip portions 14 approximately in prism shape arranged mutually apart in the base portions 13. In other words, with this abrasive layer 12, individual groups are formed by a plurality of prism shaped portions 14 approximately sharing a single base portion 13, and the strength the collapse of the tip portions 14 is completely ensured. Additionally, with this abrasive sandpaper 1, the base portions 13 are mutually segregated by the groove portions 15, and portions that have no abrasive material exist between adjacent groups. Therefore, the flexibility of the abrasive sandpaper 1 is completely ensured, unlike a case where all the tip portions 14 are connected to the base portion 13.
    [058] Consequently, with abrasive sandpaper 1, as shown schematically in Figure 8a, when an abrasion object P undergoes abrasion, the substrate layer 11 flexes and tracks the surface ripples of the abrasion object P, and in this way, the abrasive surfaces of the tip portions 14, which are formed in groups on each base portion 13, come into close contact with the object for abrasion P, and optimum abrasion can be implemented. Additionally, with abrasive sandpaper 1, the collapse resistance of the flattened tip portions 14 that originates from the detachment of the base portion 13 from the substrate layer 11 is ensured through a connection with the base portions 13, and the tension applied to the tip portions 14 can be reduced by tracking the shape of the substrate layer 11. Consequently, even if the height of the tip portions 14 is increased, disruption and detachment of the tip portions 14 can be suppressed. Furthermore, due to the fact that the volume of the abrasive layer 12 can be completely ensured by increasing the height of the tip portions 14, the service life of the abrasive sandpaper 1 can be extended.
    [059] It is noted that a decrease in the leveling of the abrasive layer 12 due to the contraction when the resin in the abrasive material is cured by light can also be suppressed by segregating the base portions 13 with groove portions 15 in the abrasive sandpaper 1, and variations in the height of the tip portions 14 (tile height) can be suppressed. In addition, by segregating the base portions 13, even in cases where bending or other forces are applied to the abrasive layer 12, decreases in the collapse resistance of the tip portions 14 due to cracks formed in the abrasive layer 12 as a result of flexion of the abrasive layer. abrasive layer 12 in portions that have no abrasive material can also be suppressed.
    [060] Additionally, in abrasive sandpaper 1, the bottom portion of the groove portions 16 between the tip portions 14 forms a round shape in the base portion 13, and the bottom portion of the groove portions 15 between the base portions. 13 forms a rounded shape on the substrate layer 11. Through this type of configuration, the collapse resistance of the tip portions 14 is additionally increased in the abrasive sandpaper 1, and breaking and detaching of the tip portions 14 can be more safely suppressed .
    [061] In contrast, for example, as shown schematically in Figure 8b, with a conventional abrasive sandpaper 50 that has all the tip portions 54 connected in a single base portion 53, there is a concern that the flexibility of a layer of substrate 51 may decrease due to the integrated shape of the abrasive layer. When a decrease in the flexibility of the substrate layer 51 occurs, the abrasive surface of the tip portions 54 does not track the surface ripples of the object for abrasion P, stress is excessively applied to the tip portions 54, and there is a concern that breakage of the tip portions 54 can occur. In addition, with the base portion 53 having an integrated shape, in cases where bending or other forces are applied to the abrasive sandpaper 50, there is a concern that the resistance to collapse of the tip portions 54 may decrease due to cracks that form. in the base portion 53.
    [062] Additionally, as shown schematically in Figure 8c, with a conventional abrasive sandpaper 60 for which a base portion is not provided and all tip portions 64 are formed directly on a substrate layer 61, at the same time as there is no problem with the flexibility of the substrate layer 61, there is a possibility that the resistance to collapse is not sufficiently ensured when the height of the tip portions 64 is increased. In this case, the tension applied to the abrasive sandpaper 60 during abrasion is concentrated on the root portion of the tip portions 64, and there is a concern that the tip portions 64 can detach easily from the substrate layer 61. Consequently, the adoption of a configuration in which a plurality of tip portions 14 are grouped by the base portions 13, as with abrasive sandpaper 1, is useful from the point of view of extending the life of the abrasive sandpaper and ensuring leveling and flexibility of the layer abrasive.
    [063] Additionally, the presence of constant ripple on the surface of the abrasion object, which is the target of abrasion, is as described above, but constant ripple is also present on the abrasion disc, conveyor belt, and other components on the equipment side. of abrasion. The abrasion disc is generally rigid, so changing the shape of the undulation is difficult. Consequently, giving the substrate layer 11 flexibility, and properly selecting the thickness and other conditions to provide abrasive sandpaper 1 with allowance for deformation is effective. The ease of attachment of the abrasive sandpaper 1 to the abrasion disc can also be ensured by giving the substrate layer 11 ample flexibility. In addition, particularly when the surface ripple of the object for abrasion and the ripple on the side of the abrasion equipment cannot be canceled only with the flexibility of the substrate layer 11, the installation of a layer 21 that has flexibility on the second surface side of the substrate layer 11 is effective. By interposing a flexible layer 21 between the abrasive sandpaper 1 and the abrasive disc, the tracking ability on the abrasive sandpaper 1 side can be further improved, and more optimum abrasion can be implemented.
    [064] As explained above, functional benefits such as those that follow are achieved according to aspects of the present invention.
    [065] One aspect of the present invention is an abrasive sandpaper used to abrasion surfaces of glass, ceramic and metal materials, the abrasive sandpaper being provided with a substrate layer and an abrasive layer provided on a first surface side of the substrate layer and including an abrasive material, and the abrasive layer having a plurality of mutually separated base portions in the substrate layer, column or trunk shaped tip portions arranged mutually apart in the base portions, and a group of grooves containing a plurality of groove portions provided between the base portions, so that the substrate layer is exposed between the base portions, with each of the grooves intercepting each other.
    [066] With this abrasive sandpaper, individual groups are formed by tip portions sharing a single base portion, and the resistance to collapse of the tip portions is completely ensured. Additionally, with this abrasive sandpaper, the flexibility of the abrasive sandpaper is completely ensured, as the base portions are mutually segregated by the groove portions, and portions having no abrasive material exist between adjacent groups. Consequently, with this abrasive sandpaper, when an abrasive object suffers abrasion, the substrate layer flexes and tracks the surface undulations of the object for abrasion, thus allowing optimal abrasion to be carried out. Additionally, with this abrasive sandpaper, the resistance to collapse of the tip portions is ensured through a connection with the base portions, and the stress applied to the tip portions can be relieved by tracking the shape of the substrate layer. Consequently, even if the height of the tip portions is increased, breakage and detachment of the tip portions can be suppressed. In addition, due to the fact that the volume of the abrasive layer can be completely ensured by increasing the height of the tip portions, the life of the abrasive sandpaper can be extended.
    [067] Additionally, in another aspect, a surface area of a top face of the base portion is 30 mm2 to 400 mm2. When selecting a strip like this, a sufficient number of tip portions can be arranged in the base portion, and an abrasion region can be ensured completely. If the surface area of the base portion is too large, there is a concern that the flexibility of the substrate layer may be lost. On the other hand, if the surface area of the base portion is very small, there is a concern that a decrease in the applicability of abrasion may occur. Consequently, in the upper surface area range, both the strength of the base portion and the flexibility of the substrate layer can be ensured.
    [068] Additionally, in another aspect, the bottom portion of the groove portions between the tip portions forms a tapered shape in the base portion. Through this, the surface area of the connection between the tip portions and the base portion is ensured, and the resistance to collapse of the tip portions can be further increased.
    [069] Additionally, in another aspect, the bottom portion of the groove portions between the base portions forms a tapered shape in the substrate layer. Through this type of configuration, the surface contact area between the substrate layer and the base portion can be completely maintained, and the joint strength in relation to the substrate layer can be ensured. Additionally, due to the fact that the root portion of the base portion does not form a notch, concentration of stresses located in the root portion of the base portion during abrasion can be avoided.
    [070] Additionally, in another aspect, the substrate layer is formed from a material that has flexibility. Giving the substrate layer flexibility to provide the abrasive sanding side with allowability for deformation is effective. In this way, the surface ripple of the abrasion object and the ripple of the abrasive disc to which the abrasive sandpaper is attached, or the like, can be absorbed, and optimal abrasion can be implemented. Additionally, as described above, due to the fact that portions that have no abrasive material exist between the base portions, impediment of the flexibility of the substrate layer due to the abrasive layer can be avoided.
    [071] Additionally, in another aspect, a layer that has flexibility is provided on the second surface side of the substrate layer. In this case, even in cases in which ripple of the object's surface for abrasion and ripple of the abrasive disc to which the abrasive sandpaper is attached, or the like, cannot be absorbed only by the flexibility of the substrate layer, the ability to trace the side Abrasive sanding can be ensured and optimum abrasion can be implemented through a layer that has flexibility.
    [072] In addition, with another aspect, the aspect ratio of the tip is from 0.2 to 10. In this range, an extension of the abrasive sandpaper life can be achieved, and the resistance to the collapse of the tip portions can be completely maintained. When the aspect ratio is reduced, the torque applied to the tip portions during abrasion decreases, and the resistance to collapse of the tip portions can be better ensured. On the other hand, when the aspect ratio is increased, the volume of the tip portions can be completely ensured, and the service life of the abrasive sandpaper 1 can be further extended. Additionally, due to the fact that the height of the groove portions between the tip portions increases, the sanding fluid can flow smoothly through the groove portions, and obstruction of the groove portions by abrasion fragments accumulating in them can be avoided.
    [073] Additionally, an aspect of the present invention is a method for abrasion of glass, ceramic and metallic materials using the abrasive paper above. The method includes a process of bonding the second surface side of the substrate layer to an abrasive disc, placing the abrasive layer and the abrasive object in contact with each other, and then rubbing with the abrasive sandpaper and a sanding fluid against the abrasive object, at the same time as the sanding fluid is introduced between the abrasion object and the abrasive layer.
    [074] With this abrasion method, when an abrasive object suffers abrasion using the abrasive paper described above, the substrate layer flexes and tracks the surface ripples of the abrasion object and the surface ripples of the abrasion disc , thus allowing optimum abrasion to be carried out. On the abrasive sanding side, the resistance to collapse of the tip portions is ensured through a connection with the base portions, and the stress applied to the tip portions can be relieved by tracking the shape of the substrate layer. Consequently, even if the height of the tip portions is increased, breakage and detachment of the tip portions can be suppressed, and due to the fact that the volume of the abrasive layer can be completely ensured, the life of the abrasive sandpaper can also be extended .
    [075] Next, a test to confirm the benefits of the present invention is described.
    [076] In this test, samples of abrasive files that have abrasive layers with different shapes were respectively manufactured, and then the front edge of each tile was inserted between a screw and a nut, and the resistance to collapse when the the bottom part was pulled was measured by a tensile tester.
    [077] Figures 9a to 9e are side views showing abrasive sandpaper sample formats according to comparative modalities and examples. With a sample S1 from Comparative Example 1 shown in Figure 9a, a base portion was not provided, and approximately prism-shaped protrusion portions 102 having a height of 0.8 mm were laid out on a substrate layer 101 for form an abrasive layer 103. In addition, the surface area of the abrasive surface was 2.6 mm x 2.6 mm.
    [078] With a sample S2 from Comparative Example 2 shown in Figure 9b, a base portion was not provided, and approximately prism-shaped protrusion portions 104 having a height of 5 mm were laid out on a substrate layer 101 to form an abrasive layer 105. In addition, the surface area of the abrasive surface was 3 mm x 3 mm. With a sample S3 from Comparative Example 3 shown in Figure 9c, a base portion was not provided, approximately prism-shaped protrusion portions 106 having a height of 5 mm were arranged on a substrate layer 101, and a layer abrasive 108 has been established with bottom portions of groove portions 107 between adjacent hump portions 106 which have a rounded shape with a radius of 0.8 mm. In addition, the surface area of the abrasive surface was 3 mm x 3 mm.
    [079] With a S4 sample of a Modality 1 shown in Figure 9d, the base portions 109 having a height of 1 mm were arranged in a layer of substrate 101, tip portions 110 approximately in prism shape were arranged in the portions base 109 so that the height of the substrate layer 101 became 5 mm, and an abrasive layer 111 was established. In addition, the bottom portions of the groove portions 112 between the tip portions 110, and the bottom portions of the groove portions 113 between the base portions 109 were each formed having a round shape with a radius of 0.8 mm . The surface area of the abrasive surface was 3 mm x 3 mm. With an S5 sample of a Mode 2 shown in Figure 9e, an abrasive layer 115 is provided with a structure similar to that of Mode 1, except that the height of a base portion 114 was 2 mm.
    [080] Figure 10 is an illustration showing the test results. As shown in this Figure, in Comparative Example 1 where the height of the lump portion is low, the resistance to collapse is naturally high, but the collapse resistance of Mode 1 in which the tip portions are formed in groups by the base portions is slightly improved four times compared to Comparative Example 2 which has no base portions, and slightly twice compared to Comparative Example 3. Additionally, the collapse resistance of Mode 2, which has a thick base portion, is additionally improved 1.3 times compared to Modality 1.
    权利要求:
    Claims (8)
    [0001]
    1. Abrasive sandpaper used to abrasion surfaces of glass, ceramic and metallic materials; the abrasive sander CHARACTERIZED by the fact that it comprises: a substrate layer (11), and an abrasive layer (12) provided on a first surface side of the substrate layer (11) and which comprises an abrasive material; and the abrasive layer comprising: a plurality of base portions (13) arranged mutually apart on the substrate layer (11); tip portions in the shape of a column or trunk (14) arranged mutually apart in the base portions (13); and a group of grooves containing a plurality of groove portions (15) provided between the base portions (13), so that the substrate layer is exposed, with each of the grooves intercepting each other.
    [0002]
    2. Abrasive sandpaper, according to claim 1, CHARACTERIZED by the fact that a surface area of a top face of the base portion (13) is from 30 mm2 to 400 mm2.
    [0003]
    3. Abrasive sandpaper according to claim 1 or 2, CHARACTERIZED by the fact that a bottom portion of the groove portions (15) between the tip portions (14) forms a tapered shape in the base portion.
    [0004]
    4. Abrasive sandpaper according to any one of claims 1 to 3, CHARACTERIZED by the fact that a bottom portion of the groove portions (15) between the base portions (13) forms a tapered shape in the substrate layer (11 ).
    [0005]
    Abrasive sandpaper according to any one of claims 1 to 4, CHARACTERIZED by the fact that a substrate layer (11) is formed of a material that has flexibility.
    [0006]
    6. Abrasive sandpaper according to any one of claims 1 to 5, CHARACTERIZED by the fact that a layer that has flexibility is provided on a second surface side of the substrate layer (11).
    [0007]
    7. Abrasive sandpaper according to any one of claims 1 to 6, CHARACTERIZED by the fact that an aspect ratio of the tip portions (14) is 0.2 to 10.
    [0008]
    8. Method for abrasion of glass, ceramic and metallic materials using an abrasive sandpaper, as defined in any one of claims 1 to 7; CHARACTERIZED by the fact that the abrasion method comprises a process of connecting the second surface side of the substrate layer (11) to an abrasion disc, placing the abrasive layer (12) and the abrasion object in contact with each other , and then rub relative to the abrasive sandpaper and a sanding fluid against the abrasive object, at the same time as the sanding fluid is introduced between the abrasion object and the abrasive layer (12).
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    同族专利:
    公开号 | 公开日
    KR102145336B1|2020-08-18|
    US9415480B2|2016-08-16|
    WO2014011517A1|2014-01-16|
    BR112015000772A2|2019-11-05|
    CN104837593A|2015-08-12|
    TW201404542A|2014-02-01|
    CN104837593B|2018-09-21|
    EP2872292A1|2015-05-20|
    KR20150032576A|2015-03-26|
    EP2872292A4|2016-03-16|
    JP2014018893A|2014-02-03|
    TWI595976B|2017-08-21|
    US20150158141A1|2015-06-11|
    JP6188286B2|2017-08-30|
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    法律状态:
    2018-12-04| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
    2019-12-03| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|
    2020-06-30| B06A| Notification to applicant to reply to the report for non-patentability or inadequacy of the application according art. 36 industrial patent law|
    2020-11-10| B09A| Decision: intention to grant|
    2021-01-19| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 08/07/2013, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    JP2012-158007|2012-07-13|
    JP2012158007A|JP6188286B2|2012-07-13|2012-07-13|Polishing pad and glass, ceramics, and metal material polishing method|
    PCT/US2013/049513|WO2014011517A1|2012-07-13|2013-07-08|Abrasive pad and method for abrading glass, ceramic, and metal materials|
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