Login| Sign Up| Help| Contact|

Patent Searching and Data


Title:
ABRASIVE MEMBER AND METHOD FOR MANUFACTURING ABRASIVE MEMBER
Document Type and Number:
WIPO Patent Application WO/2019/135177
Kind Code:
A1
Abstract:
Object: Provided is an abrasive member that does not readily degrade in abrasion performance and is capable of maintaining excellent abrasion performance for a long duration, and a method for manufacturing such an abrasive member. Solution: An abrasive member including a substrate, abrasive grains surface-treated with a surface treatment agent containing a benzene ring substituted with two or more hydroxy groups, and a binder binding the substrate and the abrasive grains.

Inventors:
ARAZOE, Hiroki (6-7-29 Kitashinagawa, Shinagawa-ku, Tokyo, 〒141-8684, JP)
IHARA, Taiki (6-7-29 Kitashinagawa, Shinagawa-ku, Tokyo, 〒141-8684, JP)
SUGIYAMA, Naota (6-7-29 Kitashinagawa, Shinagawa-ku, Tokyo, 〒141-8684, JP)
TOYOTA, Mayumi (6-7-29 Kitashinagawa, Shinagawa-ku, Tokyo, 〒141-8684, JP)
MASUDA, Shoichi (6-7-29 Kitashinagawa, Shinagawa-ku, Tokyo, 〒141-8684, JP)
Application Number:
IB2019/050026
Publication Date:
July 11, 2019
Filing Date:
January 02, 2019
Export Citation:
Click for automatic bibliography generation   Help
Assignee:
3M INNOVATIVE PROPERTIES COMPANY (3M Center, Post Office Box 33427Saint Paul, Minnesota, 55133-3427, US)
International Classes:
C09K3/14; B24D11/00
Domestic Patent References:
WO2018236967A12018-12-27
Foreign References:
US20170338476A12017-11-23
CN104788701A2015-07-22
JPH09201232A1997-08-05
Attorney, Agent or Firm:
MEDVED, Aleksander et al. (3M Center, Office of Intellectual Property CounselPost Office Box 3342, Saint Paul Minnesota, 55133-3427, US)
Download PDF:
Claims:
Scope of Claims

1. An abrasive member comprising:

a substrate;

abrasive grains surface-treated with a surface treatment agent containing a benzene ring and two or more hydroxy groups directly bonded to the benzene ring; and

a binder binding the substrate and the abrasive grains.

2. The abrasive member according to claim 1, wherein the surface treatment agent contains a catechol group.

3. The abrasive member according to claim 1 or 2, wherein the substrate is a non-woven fabric substrate.

4. A method for manufacturing an abrasive member, the method comprising:

a surface treatment step of mixing a surface treatment agent containing a benzene ring and two or more hydroxy groups directly bonded to the benzene ring and abrasive grains in a solvent to surface-treat the abrasive grains and obtain a treated liquid containing surface-treated abrasive grains;

an addition step of adding a binder resin to the treated liquid to obtain a coating liquid containing the surface-treated abrasive grains and the binder resin; and

a coating step of coating a substrate with the coating liquid to obtain an abrasive member containing the substrate and the surface-treated abrasive grains adhered to the substrate.

5. The manufacturing method according to claim 4, wherein the surface treatment agent contains a catechol group.

6. The manufacturing method according to claim 4 or 5, wherein the substrate is a non- woven fabric substrate.

7. Abrasive grains surface-treated with a surface treatment agent comprising a benzene ring and two or more hydroxy groups directly bonded to the benzene ring.

Description:
ABRASIVE MEMBER AND METHOD FOR MANUFACTURING ABRASIVE MEMBER

TECHNICAL FIELD

The present invention relates to an abrasive member and a method for manufacturing an abrasive member.

BACKGROUND ART

As one type of abrasive member, abrasive members in which abrasive grains are adhered via resin to a substrate such as non-woven fabric have been used in the related art. For example, Patent Document 1 describes an abrasive tool which uses an abrasive sheet which support abrasive grains with a binder resin.

PRIOR ART DOCUMENTS

Patent Document 1: JP H9-201232A

SUMMARY OF THE INVENTION

Problem to be Solved by the Invention

In the above abrasive member, it is desired that degradation of abrasion performance due to grains detaching during use or the like be suppressed and that high abrasion performance be maintained even when used for a long duration.

An object of the present invention is to provide an abrasive member that does not readily degrade in abrasion performance and is capable of maintaining excellent abrasion performance for a long duration, and a method for manufacturing such an abrasive member.

MEANS FOR SOLVING THE PROBLEM

One aspect of the present invention relates to an abrasive member that includes a substrate, abrasive grains surface -treated with a surface treatment agent containing a benzene ring and two or more hydroxy groups directly bonded to the benzene ring, and a binder that binds the substrate and the abrasive grains.

In one embodiment, the surface treatment agent may contain a catechol group.

In one embodiment, the substrate may be a non-woven fabric substrate.

Another aspect of the present invention relates to a method for manufacturing an abrasive member, the method including: a surface treatment step of mixing a surface treatment agent containing a benzene ring and two or more hydroxy groups directly bonded to the benzene ring and abrasive grains in a solvent to surface -treat the abrasive grains and obtain a treated liquid containing surface-treated abrasive grains; an addition step of adding a binder resin to the treated liquid to obtain a coating liquid containing the surface-treated abrasive grains and the binder resin; and a coating step of coating a substrate with the coating liquid to obtain an abrasive member containing the substrate and the surface-treated abrasive grains adhered to the substrate.

In one embodiment, the surface treatment agent may contain a catechol group.

In one embodiment, the substrate may be a non-woven fabric substrate.

EFFECT OF THE INVENTION

According to the present invention, provided is an abrasive member that does not readily degrade in abrasion performance and is capable of maintaining excellent abrasion performance for a long duration, and a method for manufacturing such an abrasive member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustrating an embodiment of an abrasive member.

FIG. 2 is an enlarged view illustrating a portion of the abrasive member illustrated in FIG.

1

FIG. 3 is a perspective view illustrating another embodiment of an abrasive member.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Preferred embodiments of the present invention are described below with reference to the drawings. Note that identical elements are assigned identical codes in the explanation of the drawings, and a duplicate explanation is omitted. Furthermore, the drawings are drawn with a portion embellished in order to ease understanding, and the dimensional ratios and the like are not limited to those shown in the drawings.

Abrasive member

The abrasive member according to the present embodiment includes a substrate, abrasive grains surface-treated with a surface treatment agent containing a benzene ring and two or more hydroxy groups directly bonded to the benzene ring, and a binder that binds the substrate and the abrasive grains.

According to the abrasive member according to the present invention, an abrasive member that does not readily degrade in abrasion performance and is capable of maintaining excellent abrasion performance for a long duration can be easily manufactured. In the abrasive member according to the present embodiment, because the abrasive grains in the abrasive member are surface-treated with a prescribed surface treatment agent, they are firmly bound to the substrate with a binder and detachment of abrasive grains during use is suppressed. The substrate is not particularly limited and may be a substrate to which abrasive grains can be adhered by a binder. Examples of the substrate include non-woven fabric substrates, paper substrates, film substrates, cloth substrates, and scrim substrates.

The type and shape of the abrasive grains may be selected as appropriate according to the application of the abrasive member. The material of the abrasive grains is preferably an inorganic material and more preferably a metal oxide from the perspective that surface treatment with a surface treatment agent is easy. Specific examples of the abrasive grains include alumina powder, and chromium oxide powder.

The average particle size of the abrasive grains may be, for example, not less than 0.1 pm, and preferably not less than 1 pm. Furthermore, the average particle size of the abrasive grains may be, for example, not greater than 1000 pm, and preferably not greater than 800 pm. Note that the average particle size of the abrasive grains in the present specification indicates a value measured in accordance with JIS R 6003 (1998).

The surface treatment agent contains a benzene ring and two or more hydroxy groups directly bonded to the benzene ring. The surface treatment agent may contain, for example, a catechol group. Furthermore, the surface treatment agent may contain a group that can be substituted for the catechol group (for example, l,2-methoxybenzene, and l,2-benzoquinone), and in this case, the group is substituted for the catechol group during surface treatment. Note that a catechol group indicates a group containing a benzene ring and two hydroxy groups respectively bonded directly to two adjacent carbon atoms on the benzene ring. In the catechol group, groups other than the above hydroxy groups may be further bonded to the benzene ring. For example, the catechol group may be a group containing a benzene ring and three hydroxyl groups respectively bonded directly to three adjacent carbon atoms on the benzene ring. Such a group may also be referred to as a pyrogallol group.

The surface treatment agent bonds to the abrasive grain surface via the two or more hydroxy groups directly bonded to the benzene ring. In particular, because the hydroxy groups are adjacent to each other on the benzene ring, the catechol group bonds more firmly to the abrasive grain surface.

The surface treatment agent may be polymerized to form a polymer. In this case, the abrasive grain surface is modified with the polymer of the surface treatment agent. In this embodiment, the abrasive grains and the binder resin (or a cured product thereof) are adhered more firmly by the polymer, and detachment of abrasive grains can be remarkably suppressed.

Examples of the surface treatment agent containing a catechol group include the compounds represented by Formula (1) below. Formula 1

In the formula, R 1 , R 2 , R 3 , and R 4 each independently represent a monovalent group; R 1 and R 2 , R 2 and R 3 , as well as R 3 and R 4 each may bond to each other to form a ring. Examples of the monovalent group of R 1 , R 2 , R 3 , and R 4 include a halogen atom, an alkyl group, an aryl group, a hydroxy group, a carbonyl group, and an ester group.

Examples of the surface treatment agent containing a pyrogallol group include the compounds represented by Formula (2) below.

Formula 2

In the formula, R a , R b , and R c each independently represent a monovalent group; R a and R b as well as R b and R c each may bond to each other to form a ring. Examples of the monovalent group of R a , R b , and R c include a halogen atom, an alkyl group, an aryl group, a hydroxy group, a carbonyl group, and an ester group.

Examples of the surface treatment agent containing a catechol group include catechol, dopamine, 4-fluorocatechol, 4-methylcatechol, 4-chlorocatechol, 4-bromocatechol, 1,2- dihydroxynaphthalene, 2,3-dihydroxynaphthalene, l,2,4-trihydroxybenzene, 3-methoxycatechol, 3,4-dihydroxybenzaldehyde, 4-tert-butylpyrocatechol, 3,4-dihydroxybenzonitrile, 2,3- dihydroxybenzaldehyde, 3’,4’-dihydroxyacetophenone, 3,4-dihydroxybenzyl alcohol, 3,4- dihydroxybenzophenone, 4-nitrocatechol, nordihydroguaiaretic acid, methyl 3,4- dihydroxybenzoate, 4-allylpyrocatechol, sodium 6,7-dihydroxynaphthalene-2-sulfonate, 3,5-di- tert-butylcatechol, 2-(3,4-dihydroxyphenyl)ethyl alcohol, 3,4-dihydroxybenzoic acid, tiron monohydrate, pyrogallol, tannic acid, gallic acid, 5-methylpyrogallol, 2,3,6,7,10,11- hexahydroxytriphenylene, hexahydroxybenzene, 3,4,5-trihydroxybenzaldehyde, 2,3,4- trihydroxybenzaldehyde, and 2,3,4,4’-tetrahydroxydiphenylmethane.

Note that among the above compounds, pyrogallol, tannic acid, gallic acid, 5- methylpyrogallol, 2,3,6,7, 10, 1 l-hexahydroxytriphenylene, hexahydroxybenzene, 3,4,5- trihydroxybenzaldehyde, 2,3,4-trihydroxybenzaldehyde, and 2, 3,4,4’- tetrahydroxydiphenylmethane may also be called surface treatment agents containing a pyrogallol group.

The used quantity of the surface treatment agent may be a quantity that enables surface treatment of the abrasive grain surface to sufficiently proceed. The used quantity of the surface treatment agent may be, for example, not less than 0.1 parts by mass, preferably not less than 0.3 parts by mass, and more preferably not less than 0.5 parts by mass, per 100 parts by mass of abrasive grains. Furthermore, the used quantity of the surface treatment agent may be, for example, not greater than 10 parts by mass, preferably not greater than 5 parts by mass, and more preferably not greater than 3 parts by mass, per 100 parts by mass of abrasive grains.

The binder is a component that binds the substrate and the abrasive grains. The binder may contain, for example, a binder resin or a cured product thereof. Examples of the binder resin include phenolic resins, urethane resins, urea resins, and epoxy resins.

The content of the binder may be, for example, not less than 5 parts by mass and preferably not less than 10 parts by mass per 100 parts by mass of abrasive grains. Furthermore, the content of the binder may be, for example, not greater than 200 parts by mass and preferably not greater than 150 parts by mass per 100 parts by mass of abrasive grains.

The abrasive member according to the present embodiment may be formed by coating a substrate with a coating liquid containing surface-treated abrasive grains and a binder resin, and then performing either one or both of drying and curing of the coating liquid. Furthermore, the abrasive member according to the present embodiment may be manufactured by the method for manufacturing an abrasive member described below.

Method for manufacturing abrasive member

The method for manufacturing an abrasive member according to the present embodiment includes: a surface treatment step of mixing a surface treatment agent containing a benzene ring and two or more hydroxy groups directly bonded to the benzene ring and abrasive grains in a solvent to surface-treat the abrasive grains and obtain a treated liquid containing surface-treated abrasive grains; an addition step of adding a binder resin to the treated liquid to obtain a coating liquid containing the surface-treated abrasive grains and the binder resin; and a coating step of coating a substrate with the coating liquid to obtain an abrasive member containing the substrate and the surface-treated abrasive grains adhered to the substrate.

According to the manufacturing method according to the present invention, an abrasive member that does not readily degrade in abrasion performance and is capable of maintaining excellent abrasion performance for a long duration can be easily manufactured. In the abrasive member obtained by the manufacturing method according to the present embodiment, the abrasive grains in the abrasive member are surface-treated with a prescribed surface treatment agent, detachment of abrasive grains during use can be suppressed. Furthermore, in the manufacturing method according to the present embodiment, the binder resin is added to the solvent without removing the abrasive grains after the surface treatment step from the solvent. As a result, aggregation of the surface-treated abrasive grains is suppressed and an abrasive member having excellent abrasion performance is obtained.

Each of the steps of the manufacturing method according to the present embodiment are described in detail below.

Surface treatment step

The surface treatment step is a step in which the surface treatment agent and the abrasive grains are mixed in a solvent (also referred to as“surface treatment solvent” hereinafter) to surface-treat the abrasive grains. A treated liquid containing surface-treated abrasive grains is obtained through the surface treatment step.

The type and shape of the abrasive grains may be selected as appropriate according to the application of the abrasive member. The material of the abrasive grains is preferably an inorganic material and more preferably a metal oxide from the perspective that surface treatment with a surface treatment agent is easy. Specific examples of the abrasive grains include alumina powder, and chromium oxide powder.

The average particle size of the abrasive grains may be, for example, not less than 0.1 pm, and preferably not less than 1 pm. Furthermore, the average particle size of the abrasive grains may be, for example, not greater than 1000 pm, and preferably not greater than 800 pm. Note that the average particle size of the abrasive grains in the present specification indicates a value measured in accordance with JIS R 6003 (1998).

The surface treatment agent contains a benzene ring and two or more hydroxy groups directly bonded to the benzene ring. The surface treatment agent may contain, for example, a catechol group. Furthermore, the surface treatment agent may contain a group that can be substituted for the catechol group (for example, l,2-methoxybenzene, and l,2-benzoquinone), and in this case, the group is substituted for the catechol group during surface treatment. Note that a catechol group represents a group containing a benzene ring and two hydroxy groups respectively bonded directly to two adjacent carbon atoms on the benzene ring. In the catechol group, groups other than the above hydroxy groups may be further bonded to the benzene ring. For example, the catechol group may be a group containing a benzene ring and three hydroxyl groups respectively bonded directly to three adjacent carbon atoms on the benzene ring. Such a group may also be referred to as a pyrogallol group. Examples of the surface treatment agent containing a catechol group are the same as above.

The surface treatment agent bonds to the abrasive grain surface via the two or more hydroxy groups directly bonded to the benzene ring. In particular, because the hydroxy groups are adjacent to each other on the benzene ring, the catechol group bonds more firmly to the abrasive grain surface.

The surface treatment agent may be polymerized to form a polymer. In this case, the abrasive grain surface is modified with the polymer of the surface treatment agent. In this embodiment, the abrasive grains and the binder resin (or a cured product thereof) are adhered more firmly by the polymer, and detachment of abrasive grains can be suppressed.

Note that when the abrasive grains after the surface treatment step are removed from the solvent and dried, pronounced aggregation of the surface-treated abrasive grains tends to occur.

The used quantity of the surface treatment agent may be a quantity that enables surface treatment of the abrasive grain surface to sufficiently proceed. The used quantity of the surface treatment agent may be, for example, not less than 0.1 parts by mass, preferably not less than 0.3 parts by mass, and more preferably not less than 0.5 parts by mass, per 100 parts by mass of abrasive grains. Increasing the quantity of the surface treatment agent proceeds surface treatment of the abrasive grain surface more quickly and thereby the above effect is more prominently exhibited. Furthermore, the used quantity of the surface treatment agent may be, for example, not greater than 10 parts by mass, preferably not greater than 5 parts by mass, and more preferably not greater than 3 parts by mass, per 100 parts by mass of abrasive grains.

The surface treatment solvent is not particularly limited and may be a solvent capable of dissolving the surface treatment agent and in which the surface treatment reaction proceeds. For example, l-methoxy-2 -propanol, isopropanol, water may be advantageously used as the surface treatment solvent. One type alone or a mixture of two or more types of surface treatment solvent may be used.

The used quantity of the surface treatment solvent is not particularly limited and may be a quantity that results in a concentration at which the surface treatment reaction sufficiently proceeds.

In the surface treatment step, the surface treatment agent may be added to a mixture of the surface treatment solvent and the abrasive grains, or the abrasive grains may be added to a mixture of the surface treatment solvent and the surface treatment agent, or the surface treatment agent and the abrasive grains may be added simultaneously to the surface treatment solvent. Furthermore, in the surface treatment step, after the surface treatment agent and the abrasive grains are added to the surface treatment solvent, surface treatment may be carried out while the system is stirred or while it is left still.

The temperature of the surface treatment step is not particularly limited and may be a temperature at which the surface treatment reaction sufficiently proceeds. The temperature during surface treatment may be, for example, equal to or higher than room temperature, not lower than 60°C, or not lower than 80°C, and may be not higher than l00°C or not higher than 95°C. The surface treatment duration of the surface treatment step is not particularly limited and may be a duration at which the surface treatment reaction sufficiently proceeds. The surface treatment duration may be, for example, not less than 1 hour or not less than 10 hours, and may be not greater than 72 hours or not greater than 64 hours.

A treated liquid containing surface-treated abrasive grains is obtained in the surface treatment step. Here, when the solvent is completely removed from the treated liquid or when the surface-treated abrasive grains are removed from the treated liquid, the surface-treated abrasive grains may aggregate, possibly resulting in unevenness in abrasion performance, detachment of the abrasive grains, and difficulty in preparing the coating liquid. In the manufacturing method according to the present embodiment, the above excellent effect is exhibited due to the treated liquid being submitted to the addition step in a state where it contains the surface-treated abrasive grains.

The treated liquid typically contains at least a portion of the surface treatment solvent. The treated liquid may be the unaltered mixture after surface treatment, or it may be the liquid obtained by removing a portion of the surface treatment solvent from the mixture after surface treatment. Furthermore, the treated liquid may be a liquid obtained by further adding another solvent to the mixture after surface treatment. The other solvent may be the same as or different than the surface treatment solvent. Examples of the other solvent include the coating solvent described below.

The treated liquid contains preferably not less than 10 parts by mass of solvent and more preferably not less than 20 parts by mass of solvent per 100 parts by mass of surface-treated abrasive grains. As a result, aggregation of the surface-treated abrasive grains is markedly suppressed.

Addition step

The addition step is a step in which a binder resin is added to the treated liquid obtained in the surface treatment step to obtain a coating liquid containing the surface-treated abrasive grains and the binder resin.

The binder resin may be a resin material capable of binding the substrate and the surface- treated abrasive grains. For example, the binder resin may be a heat-curable resin material capable of binding the substrate and the surface-treated abrasive grains through curing.

Examples of the binder resin include phenolic resins, urethane resins, urea resins, and epoxy resins.

The added quantity of the binder resin may be a quantity that enables binding of the substrate and the surface-treated abrasive grains via a coating step described below. The added quantity of the binder resin may be, for example, not less than 5 parts by mass and preferably not less than 10 parts by mass per 100 parts by mass of abrasive grains before surface treatment. Furthermore, the added quantity of the binder resin may be, for example, not greater than 200 parts by mass and preferably not greater than 150 parts by mass per 100 parts by mass of abrasive grains before surface treatment.

The ratio (M/R) of abrasive grains (M) to the quantity of binder resin (R) is, for example, preferably not less than 0.5, and more preferably not less than 0.75. As a result, abrasive force tends to further improve. Furthermore, the ratio (M/R) is, for example, preferably not greater than 20, and more preferably not greater than 10. As a result, detachment of the abrasive grains is markedly suppressed.

In the addition step, components other than the binder resin may also be added to the treated liquid. For example, a coating solvent may be further added in the addition step. The coating solvent may be a solvent that can dissolve the binder resin and that can be removed from on top of the substrate after coating in the coating step. Examples of the coating solvent include 1- methoxy -2 -propanol, and isopropanol.

The coating liquid obtained in the coating step contains, as solvents, one or more types selected from the group consisting of the surface treatment solvents and the coating solvents.

When a coating solvent is added to the coating liquid, the surface treatment solvent may be included in the coating liquid or may be removed from the coating liquid.

The viscosity of the coating liquid is not particularly limited and may be varied as appropriate according to the coating method employed in the coating step described below.

The solids concentration of the coating liquid after coating is not particularly limited and may be varied as appropriate according to the coating method employed in the coating step described below and the adhered quantity of solids needed in the abrasive member. For example, the solids concentration of a spray coating liquid in the coating step described below is preferably not less than 50 mass%.

Coating step

The coating step is a step in which the substrate is coated with the coating liquid to obtain the abrasive member. An abrasive member containing a substrate and surface-treated abrasive grains adhered to the substrate is obtained through the coating step.

The substrate is not particularly limited and may be a substrate to which abrasive grains can be adhered by a binder resin. Examples of the substrate include non-woven fabric substrates, paper substrates, film substrates, cloth substrates, and scrim substrates.

The coating method of the coating liquid is not particularly limited and may be a method capable of uniformly coating the substrate with the coating liquid. Examples of the coating method include spray coating, and dip coating.

The applied quantity of the coating liquid may be varied as appropriate according to the application of the abrasive member. For example, the applied quantity of the coating liquid is a quantity that results in the quantity of abrasive grains per unit area of the substrate surface (abrasive grain standard before surface treatment) being preferably not less than 0.01 g/cm 2 and more preferably not less than 0.05 g/cm 2 , and preferably not greater than 1.0 g/cm 2 and more preferably not greater than 0.5 g/cm 2 .

In the coating step, the solvent may be removed after the substrate is coated with the coating liquid. In the present embodiment, the solvent may be removed by, for example, volatilization by either one or both of heat and reduced pressure. Furthermore, in the coating step, the binder resin may be cured after the substrate is coated with the coating liquid. In the present embodiment, the binder resin may be cured by, for example, either one or both of heat and irradiation with light. Removal of the solvent and curing of the binder resin may be carried out separately or simultaneously.

According to the manufacturing method according to the present embodiment, an abrasive member containing a substrate, surface-treated abrasive grains adhered to the substrate, and a binder that binds the substrate and the surface-treated abrasive grains is obtained. Here, the binder contains a binder resin or a cured product thereof, and firmly holds the abrasive grains on the substrate. In the present embodiment, the surface -treated abrasive grains have excellent abrasion performance because they are adhered to the substrate in a well dispersed manner. Furthermore, in the abrasive member of the present embodiment, due to the fact that the abrasive grains are surface-treated, adhesiveness between the binder and the abrasive grains is good, detachment of the abrasive grains is suppressed, and excellent abrasion performance can be maintained for a long duration.

A preferred embodiment of the abrasive member obtained by the manufacturing method according to the present embodiment is described below with reference to the drawings. FIG. 1 is a perspective view illustrating an embodiment of an abrasive member; FIG. 2 is an enlarged view illustrating a portion of the abrasive member indicated by 2A in FIG. 1.

An abrasive member 10 includes a non-woven fabric 11, abrasive grains 12 adhered to fibers 111 which constitute the non-woven fabric 11, and a binder 13 which binds the abrasive grains 12 and the fibers 111. The abrasive grains 12 are surface-treated abrasive grains that are surface-treated with a surface treatment agent, and are adhered to the fibers 111 via the binder 13. The binder 13 contains a binder resin or a cured product thereof, adheres to a portion of the surface of the fibers 111 and holds the abrasive grains 12 on the fibers 111.

The adhesiveness of the abrasive grains 12 with the binder 13 is considered to improve through surface treatment, and detachment of the abrasive grains 12 during use is considered to be suppressed as a result. Furthermore, the abrasive grains 12 do not substantially form any aggregates, and adhere to the non-woven fabric 11 in a highly dispersed manner. As a result, the abrasive member 10 has excellent abrasion performance and can also exhibit uniform abrasion performance across the entire abrasion region. In the present embodiment, the shape of the abrasive member is not limited to the disk shape illustrated in FIG. 1. For example, FIG. 3 is a perspective view illustrating another embodiment of the abrasive member. The abrasive member 20 illustrated in FIG. 3 includes a non- woven fabric 21 molded into a wheel shape, abrasive grains and a binder (not illustrated) adhered to the non-woven fabric 21, and a core member 22 which supports the non-woven fabric 21. The material that constitutes the core member 22 is not particularly limited and may be, for example, Bakelite.

Although descriptions were given above for the preferred embodiments of the present invention, the present invention is not limited to the aforementioned embodiments.

For example, one aspect of the present invention relates to abrasive grains surface-treated with a surface treatment agent containing a benzene ring and two or more hydroxy groups directly bonded to the benzene ring.

In one embodiment, the above abrasive grains may be surface-modified with a surface treatment agent. Here, surface modification indicates that the surface treatment agent or a component derived from the surface treatment agent (for example, a polymer of the surface treatment agent) is bonded to the abrasive grain surface. Note that the components bound to the abrasive grain surface may be analyzed by, for example, time-of-flight secondary ion mass spectrometry (TOF-SIMS).

EXAMPLES

The present invention will be described more specifically below using examples, but the present invention is not intended to be limited to the examples.

Example 1

2.75 g of 3-hydroxytyramine hydrochloride (dopamine hydrochloride), 65 g of l-methoxy- 2 -propanol, and 10 g of distilled water were mixed at room temperature to prepare a dopamine solution. 275 g of alumina powder (Morundum A-43, available from Showa Denko K.K. (Minato- ku, Tokyo)) was added to the dopamine solution, this was left to stand for 18 hours at room temperature, and a treated liquid containing alumina powder surface-treated with dopamine was obtained. The obtained treated liquid and 150 g of resol-type phenolic resin (BRS-300, available from Aica Kogyo Co., Ltd.) were mixed and stirred well to obtain a coating liquid.

The coating liquid was applied to a non-woven fabric (thickness 6 mm) using a spray coater. The applied quantity was such that the weight per unit area of the non-woven fabric was from 35 mg/cm 2 to 60 mg/cm 2 . The coated non-woven fabric was put in a l65°C oven for 10 minutes to dry and cure it, and an abrasive member was obtained.

An abrasive force evaluation was performed for the obtained abrasive member by the method below. Method of abrasive force evaluation

The abrasive member was cut into a disk 10 cm in diameter to obtain a test piece for evaluation. Then, the test piece for evaluation and a polymethyl methacrylate (PMMA) sheet 3 mm thick were set in a Schiefer abrasion tester, and the test piece for evaluation was rotated 6000 times while a small quantity of water was supplied. The weight loss of the PMMA sheet was measured after 1000 rotations, 2000 rotations, 4000 rotations, and 6000 rotations, and abrasive force was evaluated. The weight loss at each number of rotations is shown in Table 1 as the cumulative abraded quantity at a number of abrasion cycles from 1000 to 6000 times.

Example 2

2.75 g of tannic acid, 65 g of l-methoxy-2 -propanol, and 10 g of distilled water were mixed at room temperature to prepare a tannic acid solution. 275 g of alumina powder (Morundum A-43, available from Showa Denko K.K. (Minato-ku, Tokyo)) was added to the tannic acid solution, this was left to stand for 18 hours at room temperature, and a treated liquid containing alumina powder surface-treated with tannic acid was obtained. The obtained treated liquid and 150 g of resol-type phenolic resin (BRS-300, available from Aica Kogyo Co., Ltd.) were mixed and stirred well to obtain a coating liquid.

An abrasive member was made in the same manner as Example 1 using this coating liquid. The same abrasive force evaluation as in Example 1 was performed for the obtained abrasive member.

Example 3

2.75 g of gallic acid hydrate, 65 g of l-methoxy-2 -propanol, and 10 g of distilled water were mixed at room temperature to prepare a gallic acid solution. 275 g of alumina powder (Morundum A-43, available from Showa Denko K.K. (Minato-ku, Tokyo)) was added to the gallic acid solution, this was left to stand for 18 hours at room temperature, and a treated liquid containing alumina powder surface -treated with gallic acid was obtained. The obtained treated liquid and 150 g of resol-type phenolic resin (BRS-300, available from Aica Kogyo Co., Ltd.) were mixed and stirred well to obtain a coating liquid.

An abrasive member was made in the same manner as Example 1 using this coating liquid. The same abrasive force evaluation as in Example 1 was performed for the obtained abrasive member.

Example 4

2.75 g of pyrogallol, 65 g of l-methoxy-2 -propanol, and 10 g of distilled water were mixed at room temperature to prepare a pyrogallol solution. 275 g of alumina powder (Morundum A-43, available from Showa Denko K.K. (Minato-ku, Tokyo)) was added to the pyrogallol solution, this was left to stand for 18 hours at room temperature, and a treated liquid containing alumina powder surface-treated with pyrogallol was obtained. The obtained treated liquid and 150 g of resol-type phenolic resin (BRS-300, available from Aica Kogyo Co., Ltd.) were mixed and stirred well to obtain a coating liquid.

An abrasive member was made in the same manner as Example 1 using this coating liquid. The same abrasive force evaluation as in Example 1 was performed for the obtained abrasive member.

Comparative Example 1

385 g of alumina powder (Morundum A-43, available from Showa Denko K.K. (Minato- ku, Tokyo)), 210 g of resol-type phenolic resin (BRS-300, available from Aica Kogyo Co., Ltd.), 91 g of l-methoxy-2 -propanol, and 14 g of distilled water were mixed and stirred well to obtain a coating liquid.

The coating liquid was applied to a non-woven fabric (thickness 6 mm) using a spray coater. The applied quantity was such that the weight per unit area of the non-woven fabric was from 35 mg/cm 2 to 60 mg/cm 2 . The coated non-woven fabric was put in a l65°C oven for 10 minutes to dry and cure it, and an abrasive member was obtained. The same abrasive force evaluation as in Example 1 was performed for the obtained abrasive member.

The evaluation results of the examples and comparative examples are shown in Table 1.

Table 1

As shown in Table 1, with the abrasive members of the examples, a large abraded quantity was achieved because the abrasive grains were surface-treated with a surface treatment agent.

Example 5

2.45 g of 3-hydroxytyramine hydrochloride (dopamine hydrochloride), 91 g of l-methoxy- 2 -propanol, and 14 g of distilled water were mixed at room temperature to prepare a dopamine solution. 245 g of alumina powder (Morundum A-43, available from Showa Denko K.K. (Minato- ku, Tokyo)) was added to the dopamine solution, this was left to stand for 18 hours at room temperature, and a treated liquid containing alumina powder surface-treated with dopamine was obtained. The obtained treated liquid and 350 g of resol-type phenolic resin (BRS-300, available from Aica Kogyo Co., Ltd.) were mixed and stirred well to obtain a coating liquid.

The coating liquid was applied to a non-woven fabric (thickness 6 mm) using a spray coater. The applied quantity was such that the weight per unit area of the non-woven fabric was from 35 mg/cm 2 to 60 mg/cm 2 . After coating, the abrasive member was cut into a ring shape having an inside diameter of 8.5 cm and an outside diameter of 16 cm, then 12 sheets were stacked. This was put in a l65°C oven to dry and cure it, and an abrasive substrate molded into a wheel shape was obtained.

An abrasive force evaluation was performed for the obtained abrasive member by the method below.

Method of abrasive force evaluation

The wheel-shaped test piece for evaluation and a copper sheet 2 mm thick were set in a robot tester, and the test piece for evaluation was rotated at 1800 rpm for 50 min while water was supplied. The weight loss of the 2 mm thick copper sheet after cumulative durations of 5 min, 10 min, 20 min, 30 min, 40 min, and 50 min were measured, and abrasive force was evaluated. The weight loss at each duration is shown in Table 2 as the cumulative abraded quantity at each duration from 5 to 50 min.

Example 6

2.45 g of tannic acid, 91 g of l-methoxy-2 -propanol, and 14 g of distilled water were mixed at room temperature to prepare a tannic acid solution. 245 g of alumina powder (Morundum A-43, available from Showa Denko K.K. (Minato-ku, Tokyo)) was added to the tannic acid solution, this was left to stand for 18 hours at room temperature, and a treated liquid containing alumina powder surface-treated with tannic acid was obtained. The obtained treated liquid and 350 g of resol-type phenolic resin (BRS-300, available from Aica Kogyo Co., Ltd.) were mixed and stirred well to obtain a coating liquid.

An abrasive member was made in the same manner as Example 5 using this coating liquid. The same abrasive force evaluation as in Example 5 was performed for the obtained abrasive member.

Example 7

2.45 g of gallic acid hydrate, 91 g of l-methoxy-2 -propanol, and 14 g of distilled water were mixed at room temperature to prepare a gallic acid solution. 245 g of alumina powder (Morundum A-43, available from Showa Denko K.K. (Minato-ku, Tokyo)) was added to the gallic acid solution, this was left to stand for 18 hours at room temperature, and a treated liquid containing alumina powder surface -treated with gallic acid was obtained. The obtained treated liquid and 350 g of resol-type phenolic resin (BRS-300, available from Aica Kogyo Co., Ltd.) were mixed and stirred well to obtain a coating liquid.

An abrasive member was made in the same manner as Example 5 using this coating liquid. The same abrasive force evaluation as in Example 5 was performed for the obtained abrasive member.

Example 8

2.45 g of pyrogallol, 91 g of l-methoxy-2 -propanol, and 14 g of distilled water were mixed at room temperature to prepare a pyrogallol solution. 245 g of alumina powder (Morundum A-43, available from Showa Denko K.K. (Minato-ku, Tokyo)) was added to the pyrogallol solution, this was left to stand for 18 hours at room temperature, and a treated liquid containing alumina powder surface-treated with pyrogallol was obtained. The obtained treated liquid and 350 g of resol-type phenolic resin (BRS-300, available from Aica Kogyo Co., Ltd.) were mixed and stirred well to obtain a coating liquid.

An abrasive member was made in the same manner as Example 5 using this coating liquid. The same abrasive force evaluation as in Example 5 was performed for the obtained abrasive member.

Comparative Example 2

325 g of alumina powder (Morundum A-43, available from Showa Denko K.K. (Minato- ku, Tokyo)), 464 g of resol-type phenolic resin (BRS-300, available from Aica Kogyo Co., Ltd.), 209 g of l-methoxy-2-propanol, and 2 g of distilled water were mixed and stirred well to obtain a coating liquid.

The coating liquid was applied to a non-woven fabric (thickness 6 mm) using a spray coater. The applied quantity was such that the weight per unit area of the non-woven fabric was from 35 mg/cm 2 to 60 mg/cm 2 . After coating, the abrasive member was cut into a ring shape having an inside diameter of 8.5 cm and an outside diameter of 16 cm, then 12 sheets were stacked. This was put in a l65°C oven to dry and cure it, and an abrasive substrate molded into a wheel shape was obtained. The same abrasive force evaluation as in Example 5 was performed for the obtained abrasive substrate molded into a wheel shape.

The evaluation results of the examples and comparative examples are shown in Table 2. Table 2

As shown in Table 2, with the abrasive members of the examples, a large abraded quantity was achieved even with the abrasive substrate molded into a wheel shape because the abrasive grains were surface-treated with a surface treatment agent.

Example 9

40 mg of tannic acid, 13 g of l-methoxy-2 -propanol, and 2 g of distilled water were mixed at room temperature to prepare a tannic acid solution. 4 g of alumina powder (Morundum A-43, available from Showa Denko K.K. (Minato-ku, Tokyo)) was added to the tannic acid solution, this was left to stand for 64 hours at room temperature, and a treated liquid containing alumina powder surface-treated with tannic acid was obtained. Alumina powder obtained by filtering the treated liquid was washed with distilled water and then put in a l00°C oven to dry, and abrasive grains were obtained.

When surface modification of the obtained abrasive grains was ascertained by time-of- flight secondary ion mass spectrometry (TOF-SIMS), a peak originating from an oxidized pyrogallol group (124 m/z) was observed in the anion spectrum obtained when a BC 2+ ion beam was irradiated. From these results it was ascertained that the abrasive grains were surface-modified with tannic acid.

Example 10

40 mg of 3-hydroxytyramine hydrochloride (dopamine hydrochloride), 13 g of l-methoxy- 2 -propanol, and 2 g of distilled water were mixed at room temperature to prepare a dopamine solution. 4 g of alumina powder (Morundum A-43, available from Showa Denko K.K. (Minato-ku, Tokyo)) was added to the dopamine solution, this was left to stand for 64 hours at room temperature, and a treated liquid containing alumina powder surface-treated with dopamine was obtained. Alumina powder obtained by filtering the treated liquid was washed with distilled water and then put in a l00°C oven to dry, and abrasive grains were obtained. When surface modification of the obtained abrasive grains was ascertained by time-of- flight secondary ion mass spectrometry (TOF-SIMS), a peak originating from an amino group (30 m/z) was observed in the anion spectrum obtained when a Bi3 2+ ion beam was irradiated. From these results it was ascertained that the abrasive grains were surface-modified with dopamine hydrochloride.