JP4519970B2 - Polishing material in which the polishing layer has a three-dimensional structure - Google Patents

Abstract

To provide an abrasive material which is excellent in loading resistance and durability, allows no attachments to attach to an abraded surface even when the end surface of the optical fiber is abraded, and is particularly suited for use in abrading a hard material such as an end surface of an optical fiber connector effectively and smoothly into a predetermined shape. The present invention provides an abrasive material for abrading an end surface of an optical fiber connector into a predetermined shape, the abrasive material having a base material (101) and an abrasive layer (102) disposed on the base material, the abrasive layer having a top layer (105) comprising an abrasive composite containing abrasive grains and a binder and a foot portion (106) comprising a binder in the absence of abrasive particles, the abrasive layer having a three-dimensional structure constructed with a plurality of regularly arranged three-dimensional elements (104) having a predetermined shape. Further, the present invention provides a method for producing an abrasive material having an abrasive layer of a three-dimensional structure, the method comprising the steps of: (1) filling a mold sheet having a plurality of regularly arranged recesses, with an abrasive material coating solution containing abrasive grains, a binder, a solvent, to a predetermined depth; (2) removing the solvent from the abrasive material coating solution in the recesses by evaporation; (3) filling the recesses further with a binder; (4) laminating a base material on the mold sheet to bond the binder to the base material; and (5) hardening the binder.

Description

砥粒／バインダー比＝2.91
砥粒／(バインダー＋添加剤) 比＝2.86
【００７３】
表２に示す成分を配合することによりラミネート用結合剤を調製した。
【００７４】
【表２】

【００７５】
図４に示す立体要素を反転させた形状の凹部を有するポリプロピレン製鋳型シートを準備した。鋳型シートに研磨材塗布液をロールコーターにより塗布し、５０℃で５分間乾燥させた。この上にラミネート用結合剤を塗布し、厚さ７５μｍの透明ポリエステルフィルムを重ね、ロールで圧力をかけてラミネートした。ポリエステルフィルムの側から紫外線を照射し、ラミネート用結合剤を硬化させた。次いで、７０℃で２４時間加熱して研磨材塗布液の結合剤を硬化させた。
【００７６】
鋳型シートを除去し、室温まで冷却して研磨材料を得た。この研磨材料は、研磨層が図４に示される縞状に配置されたプリズム形状の立体構造を有している。各寸法を表３に示す。
【００７７】
【表３】

【００７８】
この研磨材料を直径１１０ｍｍの円形に打ち抜いて研磨ディスクを作製した。
【００７９】
得られた研磨ディスクを用いて、光ファイバーコネクタ端面を研磨した。研磨条件を表４に示す。
【００８０】
【表４】

【００８１】
切削量の経時変化を図７に示す。研磨後、この光ファイバーコネクタ端面を電子顕微鏡で観察したところ、滑らかな表面が確認された。顕微鏡写真を図８に示す。
【００８２】
実施例２
表５に示す成分を配合することにより研磨材塗布液を調製した。
【００８３】
【表５】

砥粒／バインダー比＝2.86
砥粒／(バインダー＋添加剤) 比＝2.86
【００８４】
この研磨材塗布液を用いること以外は実施例１と同様にして研磨ディスクを作製し、光ファイバーコネクタ端面を研磨した。切削量の経時変化を図７に示す。研磨後、この光ファイバーコネクタ端面を電子顕微鏡で観察したところ、滑らかな表面が確認された。顕微鏡写真を図９に示す。
【００８５】
比較例１
ミネソタ・マイニング・アンド・マニュファクチュアリング社製の研磨材料「インペリアル印ダイヤモンドラッピングフィルム３ミル３ミクロンタイプＨ」を直径１１０ｍｍの円形に打ち抜いて研磨ディスクを作製した。この研磨ディスクを用いること以外は実施例１と同様にして光ファイバーコネクタ端面を研磨した。切削量の経時変化を図７に示す。研磨後、この光ファイバーコネクタ端面を電子顕微鏡で観察したところ、粗い表面が確認された。顕微鏡写真を図１０に示す。
【００８６】
比較例２
実施例１で調製した研磨材塗布液を厚さ７５μｍのポリエステルフィルムにナイフコーターを用いて塗布し、溶剤を蒸発させて除去し、厚さ１１μｍの研磨層を形成した。この研磨層を７０℃で２４時間加熱して結合剤を硬化させた。得られた研磨材料を直径１１０ｍｍの円形に打ち抜き、研磨ディスクを作製した。
【００８７】
この研磨ディスクを用いること以外は実施例１と同様にして光ファイバーコネクタ端面を研磨した。切削量の経時変化を図７に示す。研磨後、この光ファイバーコネクタ端面を電子顕微鏡で観察したところ、粗い表面が確認された。顕微鏡写真を図１１に示す。
【００８８】
比較例３
実施例２で調製した研磨材塗布液を厚さ７５μｍのポリエステルフィルムにナイフコーターを用いて塗布し、溶剤を蒸発させて除去し、厚さ１１μｍの研磨層を形成した。この研磨層を７０℃で２４時間加熱して結合剤を硬化させた。得られた研磨材料を直径１１０ｍｍの円形に打ち抜き、研磨ディスクを作製した。
【００８９】
この研磨ディスクを用いること以外は実施例１と同様にして光ファイバーコネクタ端面を研磨した。切削量の経時変化を図７に示す。研磨後、この光ファイバーコネクタ端面を電子顕微鏡で観察したところ、粗い表面が確認された。顕微鏡写真を図１２に示す。
【００９０】
図８および９と図１０とを比較すると、実施例１および２の研磨材料は現行製品である比較例１の研磨材料より滑らかな研磨表面を与えることが解る。また、図８と図１１とを比較すると、実施例１の研磨材料は、同じ研磨材塗布液から形成されているが研磨層が立体構造を有しない研磨材料である比較例２の研磨材料より滑らかな研磨表面を与えることが解る。図９と図１２とを比較すると、実施例２の研磨材料は同じ研磨材塗布液から形成されているが研磨層が立体構造を有しない研磨材料である比較例３の研磨材料より滑らかな研磨表面を与えることが解る。
【００９１】
図７のグラフより、実施例２の研磨ディスクは比較例１〜３の研磨ディスクより高い切削性を示すことが解る。
【００９２】
実施例３
表６に示す成分を配合することにより研磨材塗布液を調製した。
【００９３】
【表６】

砥粒／バインダー比＝2.00
砥粒／(バインダー＋添加剤) 比＝1.96
【００９４】
実施例１で用いたのと同じポリプロピレン製鋳型シートを準備した。鋳型シートに研磨材塗布液をロールコーターにより塗布し、６０℃で５分間乾燥させた。この上に実施例１で調製したラミネート用結合剤を塗布し、厚さ７５μｍの透明ポリエステルフィルムを重ね、ロールで圧力をかけてラミネートした。ポリエステルフィルムの側から紫外線を照射し、結合剤を硬化させた。鋳型シートを除去し、室温まで冷却して研磨材料を得た。この研磨材料を直径１１０ｍｍの円形に打ち抜いて研磨ディスクを作製した。
【００９５】
他方、光コネクタフェルールを準備し、その端面を、ミネソタ・マイニング・アンド・マニュファクチュアリング社製の研磨材料「インペリアル印ダイヤモンドラッピングフィルム３ミル０．５ミクロンタイプＨ」を用いて表７と同じ研磨条件で研磨した。
【００９６】
この光ファイバーコネクタ端面を作製した研磨ディスクを用いて研磨した。研磨条件を表７に示す。
【００９７】
【表７】

【００９８】
研磨後、この光ファイバーコネクタ端面を電子顕微鏡で観察したところ、滑らかな表面が確認された。顕微鏡写真を図１３に示す。
【００９９】
研磨後の光ファイバーコネクタ端面について、形状をダイレクト・オプティカル・リサーチ・カンパニー（ＤＯＲＣ）製「ズーム・インターフェロメーター・ＺＸ−１・ミニ・ＰＭＳ」で測定し、反射減衰量をＪＤＳ・ＦＩＴＥＬ製「バックリフレクション・メーター・ＲＭ３００Ａ」で測定した。結果を表９に示す。
【０１００】
実施例４
表８に示す成分を配合することにより研磨材塗布液を調製した。
【０１０１】
【表８】

砥粒／バインダー比＝2.00
砥粒／(バインダー＋添加剤) 比＝1.96
【０１０２】
この研磨材塗布液を用いること以外は実施例３と同様にして、研磨ディスクを作製し、光ファイバーコネクタ端面を研磨した。研磨後の端面の顕微鏡写真を図１４に示す。端面形状、および反射減衰量を表９に示す。
【０１０３】
比較例４
ミネソタ・マイニング・アンド・マニュファクチュアリング社製の研磨材料「インペリアル印ダイヤモンドラッピングフィルム３ミル０．０５ミクロンＡＯタイプＰ」を直径１１０ｍｍの円形に打ち抜いて研磨ディスクを作製した。この研磨ディスクを用いること以外は実施例３と同様にして光ファイバーコネクタ端面を研磨した。研磨後の端面の顕微鏡写真を図１５に示す。端面形状、および反射減衰量を表９に示す。
【０１０４】
比較例５
実施例３で調製した研磨材塗布液を厚さ７５μｍのポリエステルフィルムにナイフコーターを用いて塗布し、溶剤を蒸発させて除去し、厚さ４μｍの研磨層を形成した。この研磨層の上に厚さ３１μｍのポリエステルフィルムをラミネートし、紫外線を照射して結合剤を硬化させた。得られた研磨材料を直径１１０ｍｍの円形に打ち抜いて研磨ディスクを作製した。
【０１０５】
この研磨ディスクを用いること以外は実施例３と同様にして光ファイバーコネクタ端面を研磨した。しかしながら、研磨中に端面に付着物がたまり、有効に研磨ができなかった。
【０１０６】
比較例６
実施例４で調製した研磨材塗布液を厚さ７５μｍのポリエステルフィルムにナイフコーターを用いて塗布し、溶剤を蒸発させて除去し、厚さ４μｍの研磨層を形成した。この研磨層の上に厚さ３１μｍのポリエステルフィルムをラミネートし、紫外線を照射して結合剤を硬化させた。得られた研磨材料を直径１１０ｍｍの円形に打ち抜いて研磨ディスクを作製した。
【０１０７】
この研磨ディスクを用いること以外は実施例３と同様にして光ファイバーコネクタ端面を研磨した。しかしながら、研磨中に端面に付着物がたまり、有効に研磨ができなかった。
【０１０８】
【表９】

【０１０９】
図１３および１４に示されているように、実施例３および４の研磨材料を用いた場合は、ミネソタ・マイニング・アンド・マニュファクチュアリング社製の研磨材料「インペリアル印ダイヤモンドラッピングフィルム３ミル０．５ミクロンタイプＨ」での研磨で生じた研磨目（図１０）が、６０秒の研磨で消えていた。この光ファイバーコネクタ端面は非常に滑らか微細に仕上がっており、表９に示されるように、反射減衰量も比較例４と比較して非常に小さかった。実施例４の研磨材料は、冷却液として２−プロパノールを用いて研磨を行うと、特に良好な結果を示した。
【０１１０】
実施例５
表１０に示す成分を配合することにより研磨材塗布液を調製した。
【０１１１】
【表１０】

砥粒／バインダー比＝2.72
砥粒／(バインダー＋添加剤) 比＝2.69
【０１１２】
実施例１で用いたのと同じポリプロピレン製鋳型シートを準備した。鋳型シートに研磨材塗布液をロールコーターにより塗布し、７０℃で５分間乾燥させた。この上に実施例１で調製したラミネート用結合剤を塗布し、厚さ７５μｍの透明ポリエステルフィルムを重ね、ロールで圧力をかけてラミネートした。ポリエステルフィルムの側から紫外線を照射してラミネート結合剤を硬化させた。次いで、７０℃で２４時間加熱して研磨材塗布液の結合剤を硬化させた。
【０１１３】
室温まで冷却し、鋳型シートを除去して研磨材料を得た。この研磨材料を直径１１０ｍｍの円形に打ち抜き、研磨ディスクを作製した。
【０１１４】
得られた研磨ディスクを用いて、ジルコニアの丸棒（直径３ｍｍ）を研磨した。研磨条件を表１１に示す。
【０１１５】
【表１１】

【０１１６】
切削量の経時変化を図１６に示す。
【０１１７】
ついで、研磨ディスクを新しいものと取り替え、光ファイバーコネクタ端面を研磨した。研磨条件を表１２に示す。
【０１１８】
【表１２】

【０１１９】
研磨後、この光ファイバーコネクタ端面を電子顕微鏡で観察したところ、滑らかな表面が確認された。顕微鏡写真を図１７に示す。
【０１２０】
実施例６
図５に示す立体要素を反転させた形状の凹部を有するポリプロピレン製鋳型シートを用いること以外は実施例５と同様にして研磨材料を作製した。この研磨材料は、研磨層が図５に示される縞状に配置された寄せ棟形状の立体構造を有している。各寸法を表１３に示す。
【０１２１】
【表１３】

^※ｈは立体要素の高さ、ｓは立体要素の頂上部の高さ、βは図４に示された頂角である。
【０１２２】
得られた研磨材料を直径１１０ｍｍの円形に打ち抜き、研磨ディスクを作製した。この研磨ディスクを用いて、実施例５と同様にジルコニアの丸棒および光ファイバーコネクタ端面を研磨した。ジルコニアの丸棒の切削量の経時変化を図１６に示す。光ファイバーコネクタ端面を電子顕微鏡で観察したところ、滑らかな表面が確認された。顕微鏡写真を図１８に示す。
【０１２３】
実施例７
図１および２に示す立体要素を反転させた形状の凹部を有するポリプロピレン製鋳型シートを用いること以外は実施例５と同様にして研磨材料を作製した。この研磨材料は、研磨層が図１および２に示される細密充填された４面体形状の立体構造を有している。各寸法を表１４に示す。
【０１２４】
【表１４】

【０１２５】
得られた研磨材料を直径１１０ｍｍの円形に打ち抜き、研磨ディスクを作製した。この研磨ディスクを用いて、実施例５と同様にジルコニアの丸棒および光ファイバーコネクタ端面を研磨した。ジルコニアの丸棒の切削量の経時変化を図１６に示す。光ファイバーコネクタ端面を電子顕微鏡で観察したところ、滑らかな表面が確認された。顕微鏡写真を図１９に示す。
【０１２６】
実施例８
実施例５で用いたのとは別種類の図４に示す立体要素を反転させた形状の凹部を有するポリプロピレン製鋳型シートを用いること以外は実施例５と同様にして研磨材料を作製した。この研磨材料は、研磨層が図４に示される縞状に配置されたプリズム形状の立体構造を有している。各寸法を表１５に示す。
【０１２７】
【表１５】

【０１２８】
得られた研磨材料を直径１１０ｍｍの円形に打ち抜き、研磨ディスクを作製した。この研磨ディスクを用いて、実施例５と同様にジルコニアの丸棒および光ファイバーコネクタ端面を研磨した。ジルコニアの丸棒の切削量の経時変化を図１６に示す。光ファイバーコネクタ端面を電子顕微鏡で観察したところ、滑らかな表面が確認された。顕微鏡写真を図２０に示す。
【０１２９】
比較例７
ミネソタ・マイニング・アンド・マニュファクチュアリング社製の研磨材料「インペリアル印ダイヤモンドラッピングフィルム３ミル９ミクロンタイプＨ」を直径１１０ｍｍの円形に打ち抜いて研磨ディスクを作製した。この研磨ディスクを用いること以外は実施例５と同様にして、ジルコニアの丸棒および光ファイバーコネクタ端面を研磨した。ジルコニアの丸棒の切削量の経時変化を図１６に示す。光ファイバーコネクタ端面を電子顕微鏡で観察したところ、粗い表面が確認された。顕微鏡写真を図２１に示す。
【０１３０】
比較例８
実施例５で調製した研磨材塗布液を厚さ７５μｍのポリエステルフィルムにナイフコーターを用いて塗布し、溶剤を蒸発させて除去し、厚さ１４μｍの研磨層を形成した。この研磨層を７０℃で２４時間加熱し、更に１００℃で２４時間加熱して結合剤を硬化させた。室温に冷却して得られた研磨材料を直径１１０ｍｍの円形に打ち抜いて研磨ディスクを得た。
【０１３１】
この研磨ディスクを用いること以外は実施例６と同様にして、ジルコニアの丸棒および光ファイバーコネクタ端面を研磨した。ジルコニアの丸棒の切削量の経時変化を図１６に示す。光ファイバーコネクタ端面を電子顕微鏡で観察したところ、粗い表面が確認された。顕微鏡写真を図２２に示す。
【０１３２】
実施例９
表１６に示す成分を配合することにより研磨材塗布液を調製した。
【０１３３】
【表１６】

砥粒／バインダー比＝2.86
砥粒／(バインダー＋添加剤) 比＝2.82
【０１３４】
表１７に示す成分を配合することによりラミネート用結合剤を調製した。
【０１３５】
【表１７】

【０１３６】
実施例１で用いたのと同じポリプロピレン製鋳型シートを準備した。鋳型シートに研磨材塗布液をロールコーターにより塗布し、７０℃で５分間乾燥させた。この上にラミネート用結合剤を塗布し、厚さ７５μｍの透明ポリエステルフィルムを重ね、ロールで圧力をかけてラミネートした。ポリエステルフィルムの側から紫外線を照射してラミネート結合剤を硬化させた。次いで、７０℃で２４時間加熱して研磨材塗布液の結合剤を硬化させた。
【０１３７】
室温まで冷却し、鋳型シートを除去し、更に１００℃で２４時間加熱して研磨層の結合剤を硬化させた。この研磨材料を直径１１０ｍｍの円形に打ち抜いて研磨ディスクを作製した。
【０１３８】
得られた研磨ディスクを用いること以外は実施例５と同様にして、ジルコニアの丸棒および光ファイバーコネクタ端面を研磨した。ジルコニアの丸棒の切削量の経時変化を図１６に示す。光ファイバーコネクタ端面を電子顕微鏡で観察したところ、滑らかな表面が確認された。顕微鏡写真を図２３に示す。
【０１３９】
実施例１０
実施例６で用いたのと同じポリプロピレン製鋳型シートを用いること以外は実施例９と同様にして研磨材料を作製した。この研磨材料を直径１１０ｍｍの円形に打ち抜いて研磨ディスクを作製した。
【０１４０】
得られた研磨ディスクを用いること以外は実施例５と同様にして、ジルコニアの丸棒および光ファイバーコネクタ端面を研磨した。ジルコニアの丸棒の切削量の経時変化を図１６に示す。光ファイバーコネクタ端面を電子顕微鏡で観察したところ、滑らかな表面が確認された。顕微鏡写真を図２４に示す。
【０１４１】
実施例１１
図３に示す立体要素を反転させた形状の凹部を有するポリプロピレン製鋳型シートを用いること以外は実施例９と同様にして研磨材料を作製した。この研磨材料は、研磨層が図３に示される頂上が所定の高さカットされたピラミッド形状の立体構造を有している。各寸法を表１８に示す。
【０１４２】
【表１８】

^※ｈは立体要素の高さ、ｓは立体要素の頂上部の高さ、αは頂上をカットする前の立体要素の２本のリッジで挟まれた頂角である。
【０１４３】
得られた研磨材料を直径１１０ｍｍの円形に打ち抜き、研磨ディスクを作製した。この研磨ディスクを用いること以外は実施例５と同様にして、ジルコニアの丸棒および光ファイバーコネクタ端面を研磨した。ジルコニアの丸棒の切削量の経時変化を図１６に示す。光ファイバーコネクタ端面を電子顕微鏡で観察したところ、滑らかな表面が確認された。顕微鏡写真を図２５に示す。
【０１４４】
図１６のグラフより、実施例５〜１１の研磨ディスクは比較例７および８の研磨ディスクより高い切削性および長い製品寿命を示すことが解る。また、図１７〜２０、および２３〜２５と図２１および２２とを比較すると、実施例５〜１１の研磨ディスクは現行製品である比較例７の研磨ディスク、および研磨層が立体構造を有しない比較例８の研磨ディスクより滑らかな研磨表面を与えることが解る。
【図面の簡単な説明】
【図１】 本発明の一実施態様である研磨層が立体構造を有する研磨材料の断面図である。
【図２】 本発明の一実施態様である研磨層が立体構造を有する研磨材料の上面図である。
【図３】 本発明の一実施態様である研磨層が立体構造を有する研磨材料の上面図である。
【図４】 本発明の一実施態様である研磨層が立体構造を有する研磨材料の断面斜視図である。
【図５】 本発明の一実施態様である研磨層が立体構造を有する研磨材料の上面図である。
【図６】 研磨層が立体構造を有する研磨材料の製造方法の一例を模式的に示す工程図である。
【図７】 光ファイバーコネクタ端面を種々の研磨材料で研磨した場合の切削量の経時変化を示すグラフである。
【図８】 本発明の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【図９】 本発明の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【図１０】 従来技術の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【図１１】 従来技術の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【図１２】 従来技術の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【図１３】 本発明の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【図１４】 本発明の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【図１５】 従来技術の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【図１６】 ジルコニアの丸棒を種々の研磨材料で研磨した場合の切削量の経時変化を示すグラフである。
【図１７】 本発明の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【図１８】 本発明の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【図１９】 本発明の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【図２０】 本発明の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【図２１】 従来技術の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【図２２】 従来技術の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【図２３】 本発明の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【図２４】 本発明の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【図２５】 本発明の研磨材料で研磨した後の光ファイバーコネクタ端面の顕微鏡写真である。
【符号の説明】
１００、４００…研磨材料、
１０１、４０１…基材、
１０２、４０２…研磨層、
１０３、４０３…砥粒、
１０４、４０４立体要素。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a polishing material whose polishing layer has a three-dimensional structure, and in particular, a polishing layer suitable for polishing an end surface of an optical fiber equipped with a ferrule, that is, an end surface of an optical fiber connector, into a predetermined shape. Regarding materials.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, optical fiber connectors that can be easily detached are widely used for connecting optical fibers in optical fiber communication networks. In connection with an optical fiber connector, end faces of an optical fiber ferrule composed of an optical fiber and a coating portion (ferrule) covering the optical fiber are directly abutted. Therefore, the optical characteristics at the time of connection, particularly the connection loss, depends on the processing properties and accuracy of the end face of the optical fiber ferrule.
[0003]
The end face of the optical fiber ferrule is processed by a plurality of stages of polishing, but the quality depends on the processing properties and accuracy of the polishing process for final finishing. That is, the main factor of the optical fiber connection loss is the degree of the finished roughness of the end face and its inclination.
[0004]
Regarding the finished roughness of the end face of the optical fiber ferrule, a correlation with the particle size of the abrasive used for polishing has been reported. For example, for a step index type fiber, when the abrasive grain size is about 1 μm, the splice loss is about 0.5 dB, but when the abrasive grain size is about 15 μm, the splice loss is about 1.0 dB. That's it.
[0005]
In view of this correlation, it is necessary to use abrasive grains having a particle size of 10 to 15 μm in order to satisfy the standard for the optical fiber connection loss to be 1 dB or less, and the standard for the connection loss to be 0.5 dB or less is satisfied. Therefore, it is necessary to use fine grade abrasive grains having a particle size of about 1 μm or less.
[0006]
Japanese Patent Application Laid-Open No. 9-248771 discloses a binder having a base material and a polishing layer provided on the base material, the polishing layer being silica particles having an average particle diameter of 5 to 30 mμ and binding the abrasive particles. And a polishing tape for an optical fiber connector end face having a center line average roughness Ra of 0.005 to 0.2 μm.
[0007]
A fine grade polishing material such as an optical fiber connector end face polishing tape has a problem of loading. Loading means that the space between abrasive grains is filled with shavings, which rises and hinders the polishing ability. For example, when polishing the end face of the optical fiber connector, the scraped particles stay between the abrasive grains, which reduces the cutting ability of the abrasive grains. Further, the liquid used as the coolant and the lubricant does not sufficiently act between the polishing material and the end face of the optical fiber connector, and a part of the polishing layer adheres to the surface of the optical fiber connector after polishing, and the removal becomes complicated. .
[0008]
Further, when fine grains are used as the abrasive grains, the polishing time becomes longer. Conversely, if the grain size of the abrasive grains is increased, the finish of the end face of the optical fiber connector becomes rough, and the standard for optical fiber connection loss cannot be satisfied. When both are used in combination, the polishing process increases, which is complicated.
[0009]
WO92 / 13680 and WO96 / 27189 describe polishing materials in which the polishing layer has a three-dimensional structure. This polishing material has a base material and a polishing layer provided on the base material, the polishing layer is made of a polishing composite containing abrasive grains and a binder, and a plurality of polishing layers are regularly arranged. It has a three-dimensional structure composed of three-dimensional elements. As the shape of the three-dimensional element, a tetrahedral shape, a pyramid shape, a prism shape, and the like are described.
[0010]
This polishing material is loading resistant and excellent in durability. However, since the abrasive grains are uniformly dispersed throughout the polishing layer, and the abrasive grains present below the polishing layer do not work effectively, the manufacturing cost increases.
[0011]
In addition, in such a polishing material in which the polishing layer has a three-dimensional structure, an abrasive coating liquid containing abrasive grains and a binder is applied to a mold sheet having a structure, and a base material is overlapped on the mold sheet to bond a binder. It is manufactured by a method of adhering to a substrate, irradiating ultraviolet rays to cure the binder, and removing the mold sheet. In this case, the abrasive coating solution needs to have sufficient fluidity to fill the structure in the mold sheet. Further, since the ultraviolet irradiation is performed by coating the abrasive coating solution with a substrate, the abrasive coating solution should not contain volatile components.
[0012]
Therefore, the content of abrasive grains in the abrasive coating liquid cannot exceed the critical pigment volume concentration. Therefore, the polishing material in which the conventional polishing layer has a three-dimensional structure has a problem that the abrasive grain content of the polishing layer cannot be sufficiently increased.
[0013]
When the polishing conditions such as the grain size of the abrasive grains and the polishing means are compared under the same conditions, the machinability of the abrasive material decreases as the abrasive grain content decreases. In particular, in a fine grade polishing material, if the content of abrasive grains is insufficient, polishing efficiency deteriorates and polishing takes time.
[0014]
Therefore, a conventional polishing material having a three-dimensional structure of the polishing layer is inferior in machinability due to insufficient abrasive content, and is used for efficiently and smoothly polishing a hard material such as an end face of an optical fiber connector into a predetermined shape. Not suitable for.
[0015]
[Problems to be solved by the invention]
The present invention solves the above-described conventional problems. The object of the present invention is excellent in loading resistance and durability, and even when the end face of the optical fiber connector is polished, no adhered matter is attached to the polished face. An object of the present invention is to provide a polishing material suitable for use in efficiently and smoothly polishing a hard material such as a connector end face into a predetermined shape.
[0016]
[Means for Solving the Problems]
The present invention provides a polishing material used for polishing an end face of an optical fiber connector into a predetermined shape, wherein the polishing material includes a base material and a polishing layer provided on the base material, and the polishing layer is used as a constituent component for polishing. An abrasive composite comprising grains and a binder, and wherein the abrasive layer has a three-dimensional structure composed of three-dimensional elements of a predetermined shape regularly arranged; This achieves the above object.
[0017]
In the present invention, (1) an abrasive coating liquid containing abrasive grains, a binder, and a solvent is provided at a predetermined depth in a mold sheet having a plurality of regularly arranged bottom-side tapered concave portions. (2) a step of evaporating and removing the solvent from the filled abrasive coating solution; (3) a step of further filling the concave portion with a binder; and (4) a base material on the mold sheet. And a step of adhering the binder to the base material; and (5) a step of curing the binder.
[0018]
The polishing material in which the polishing layer of the present invention has a three-dimensional structure is preferably manufactured by the above-described manufacturing method.
Examples of particularly preferred embodiments of the present invention are given below.
A polishing material in which the shape of the three-dimensional element is a tetrahedral shape or a pyramid shape having a ridge connected at the top.
An abrasive material in which the shape of the three-dimensional element is a prism shape having a ridge parallel to the substrate surface at the top.
A polishing material having a size of the abrasive grains of 0.01 to 20 μm.
The binder is phenol resin, aminoplast resin, urethane resin, epoxy resin, acrylate resin, acrylated isocyanurate resin, urea-formaldehyde resin, isocyanurate resin, acrylated urethane resin, acrylated epoxy resin, glue and the like. An abrasive material selected from the group consisting of a mixture.
A polishing material wherein the abrasive grains are selected from the group consisting of molten aluminum oxide, heat treated aluminum oxide, ceramic aluminum oxide, silicon carbide, alumina zirconia, garnet, diamond, cubic boron nitride silica, and mixtures thereof.
A polishing material in which the substrate is flexible and particularly suitable for spherical polishing of the end face of an optical fiber connector.
A polishing material that provides an end face of an optical fiber connector having a connection loss of 1.0 dB or less.
The binder contained in the abrasive coating solution used in the step (1) is phenol resin, aminoplast resin, urethane resin, epoxy resin, acrylate resin, acrylated isocyanurate resin, urea-formaldehyde resin, isocyanurate resin, acrylated. A method for producing an abrasive material, wherein the abrasive layer is selected from the group consisting of a urethane resin, an acrylated epoxy resin, and a mixture thereof and having a three-dimensional structure.
The binder used in the step (3) is phenol resin, aminoplast resin, urethane resin, epoxy resin, acrylate resin, acrylated isocyanurate resin, urea-formaldehyde resin, isocyanurate resin, acrylated urethane resin, acrylated epoxy resin. And a method for producing a polishing material, wherein the polishing layer has a three-dimensional structure, selected from the group consisting of these and mixtures thereof.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a cross-sectional view of an abrasive material in which an abrasive layer according to an embodiment of the present invention has a three-dimensional structure. The abrasive material 100 is an abrasive material having a substrate 101 and an abrasive layer 102 provided on the surface of the substrate.
[0020]
Preferred materials for the substrate of the present invention include polymer films, paper, fabrics, metal films, vulcanized fibers, non-woven substrates, combinations thereof and processed products thereof. When the end surface of the optical fiber connector is polished to a spherical surface, the base material is preferably a flexible material. This is because it is easy to form a spherical shape. Moreover, it is preferable that a base material is transparent with respect to ultraviolet irradiation. This is because it is convenient in the manufacturing process.
[0021]
For example, the substrate may be a polymer film such as a polyester film. The polymer film may also be primed with a material such as polyethylene acrylic acid to promote adhesion of the abrasive composite to the substrate.
[0022]
The polishing layer 102 has as its constituent components a polishing composite that includes a binder matrix and abrasive grains 103 dispersed therein.
[0023]
The abrasive composite is formed from a slurry containing a plurality of abrasive grains dispersed in an uncured or ungelled binder. In curing or gelling, the abrasive composite is solidified, i.e., fixed to a predetermined shape and predetermined structure.
[0024]
The size of the abrasive grains varies depending on the type of abrasive grains and the application of the abrasive material. For example, the dimensions are 0.01 to 1 μm, preferably 0.01 to 0.5 μm, more preferably 0.01 to 0.1 μm in final finish polishing, and 0.5 to rough polishing for curved surface formation. ˜20 μm, preferably 0.5 to 10 μm. Examples of abrasive grains suitable for the present invention include diamond, cubic boron nitride, cerium oxide, molten aluminum oxide, heat treated aluminum oxide, sol-gel aluminum oxide, silicon carbide, chromium oxide, silica, zirconia, alumina zirconia, iron oxide, garnet. , And mixtures thereof. Particularly preferable are diamond, cubic boron nitride, aluminum oxide and silicon carbide for rough polishing, and silica and aluminum oxide for final polishing.
[0025]
The binder forms a polishing layer by curing or gelation. Examples of preferred binders for the present invention include phenolic resins, resol-phenolic resins, aminoplast resins, urethane resins, epoxy resins, acrylate resins, polyester resins, vinyl resins, melamine resins, acrylated isocyanurate resins, urea-formaldehyde. Resins, isocyanurate resins, acrylated urethane resins, acrylated epoxy resins, and mixtures thereof are included. The binder may be a thermoplastic resin.
[0026]
Particularly preferred are phenol resins, resol-phenol resins, epoxy resins, and urethane resins.
[0027]
The binder may be radiation curable. A radiation curable binder is any binder that can be at least partially cured or at least partially polymerized by irradiation energy. Depending on the binder used, energy sources such as heat, infrared, electron beam, ultraviolet irradiation or visible light irradiation are used.
[0028]
Typically, these binders are polymerized by a free radical mechanism. Preferably, these are acrylated urethanes, acrylated epoxies, aminoplast derivatives having an α, β-unsaturated carbonyl group, ethylenically unsaturated compounds, isocyanurate derivatives having at least one acrylate group, at least one It is selected from the group consisting of isocyanates having acrylate groups, and mixtures thereof.
[0029]
When the binder is cured by UV irradiation, a photoinitiator is required to initiate free radical polymerization. Examples of preferred photoinitiators for this purpose include organic peroxides, azo compounds, quinones, benzophenones, nitroso compounds, acrylic halides, hydrazones, mercapto compounds, pyrylium compounds, triacrylimidazoles, bisimidazoles, chloroalkyltriazines, benzoin ethers, Benzyl ketal, thioxanthone and acetophenone derivatives are included. A preferred photoinitiator is 2,2-dimethoxy-1,2-diphenyl-1-ethanone.
[0030]
If the binder is cured with visible radiation, the photoinitiator is required to initiate free radical polymerization. Examples of preferred photoinitiators for this purpose are U.S. Pat. No. 4,735,632, column 3, lines 25 to 4, line 10 and columns 5, 1-7, which are hereby incorporated by reference. Line, column 6, lines 1-35.
[0031]
The weight ratio of abrasive to binder is generally about 1.5 to 10 parts of abrasive for 1 part of binder, preferably about 2 to 7 parts of abrasive for 1 part of binder. Range. This ratio varies depending on the size of the abrasive grains, the type of binder used and the application of the abrasive material.
[0032]
When a hard material such as an end face of an optical fiber connector is polished smoothly and precisely, a preferable range of the concentration of abrasive grains contained in the polishing composite is as follows. 43 to 90% by weight when the abrasive is silicon carbide, 70 to 90% by weight for spherical abrasive particles such as alumina and silica, 37 to 90% by weight for alumina, and 39 to 90% for diamond. %.
[0033]
The abrasive composite may include materials other than abrasive grains and a binder. For example, conventional additives such as coupling agents, wetting agents, dyes, pigments, plasticizers, fillers, release agents, polishing aids and mixtures thereof.
[0034]
The abrasive composite can include a coupling agent. By adding a coupling agent, the coating viscosity of the slurry used to form the abrasive composite can be significantly reduced. Examples of such coupling agents preferred for the present invention include organosilanes, zircoaluminates and titanates. The amount of coupling agent is generally less than 5%, preferably less than 1% by weight of the binder.
[0035]
The polishing layer 102 has a three-dimensional structure composed of three-dimensional elements 104 having a fixed shape and regularly arranged in a plurality. The three-dimensional element 104 has a tetrahedral shape in which ridges are connected at the points of the top. In this case, the apex angle α sandwiched between the two ridges is usually 30 to 150 °, preferably 45 to 140 °. The three-dimensional element may have a pyramid shape. In that case, the apex angle between the two ridges is usually 30 to 150 °, preferably 45 to 140 °.
[0036]
The top point of the three-dimensional element 104 exists on a plane parallel to the substrate surface over almost the entire area of the abrasive material. In FIG. 1, the symbol h indicates the height of the three-dimensional element from the substrate surface. h is usually 2 to 300 μm, preferably 5 to 150 μm. The variation in the height of the top point is preferably within 20% of the height of the three-dimensional element 104, and more preferably within 10%.
[0037]
The three-dimensional elements 104 are arranged in a predetermined arrangement. In FIG. 1, the three-dimensional element 104 is closely packed. In general, the three-dimensional element is repeated at a constant cycle. This repetitive shape is unidirectional or preferably bidirectional.
[0038]
The abrasive grains do not protrude beyond the surface of the solid element shape. That is, the three-dimensional element 104 is configured with a smooth plane. For example, the surface constituting the three-dimensional element 104 has a surface roughness Ry of 2 μm or less, preferably 1 μm or less.
[0039]
It is the top 105 of the three-dimensional element 104 that performs the polishing function. While the abrasive material is subjected to polishing, the three-dimensional element decomposes from the top, and unused abrasive grains appear. Accordingly, in order to improve the machinability of the abrasive material, it is preferable to increase the concentration of abrasive grains in the abrasive composite existing at the top of the three-dimensional element as much as possible. This is because the machinability of the abrasive material is enhanced and it is suitable for use in polishing hard materials. More preferably, the concentration of the abrasive grains in the polishing composite existing at the top of the three-dimensional element is equal to or higher than the critical pigment volume concentration.
[0040]
The critical pigment volume concentration is the volume concentration of the particles when the binder just fills the gap between the particles when the particles and the binder are mixed. It has a critical concentration that has the property of losing fluidity. When the concentration of the abrasive grains in the polishing composite existing on the top of the three-dimensional element is not more than the critical pigment volume concentration, the machinability of the polishing material becomes insufficient, and it becomes unsuitable for polishing a hard material such as an end face of an optical fiber connector.
[0041]
The flange portion 106 of the three-dimensional element, that is, the lower portion of the polishing layer that adheres to the substrate does not normally exhibit a polishing function. This is because the abrasive material is usually discarded when the abrasive layer is worn to that extent. The flange 106 of the three-dimensional element that does not exhibit the polishing function does not need to contain abrasive grains, and may be formed only with a binder.
[0042]
By making the three-dimensional element 104 into such a two-layer structure, the amount of relatively expensive abrasive grains can be saved, so that a polishing material can be provided at a low cost. Moreover, since the binder of the collar part 106 can be designed considering only the adhesion performance to the base material, poor adhesion to the base material is less likely to occur.
[0043]
In FIG. 1, symbol s indicates the height of the top 105 of the three-dimensional element. For example, s is 5 to 95%, preferably 10 to 90% of the height h of the three-dimensional element.
[0044]
FIG. 2 is a top view of the polishing material. In FIG. 2, the symbol o indicates the base length of the three-dimensional element. The symbol p indicates the distance between the tops of the three-dimensional elements. o is, for example, 5 to 1000 μm, preferably 10 to 500 μm. p is, for example, 5 to 1000 μm, preferably 10 to 500 μm.
[0045]
In another aspect, the three-dimensional element may have a tetrahedral shape or a pyramid shape in which the top is cut at a predetermined height. In that case, it is preferable that the top of the three-dimensional element is constituted by a triangular or quadrangular plane parallel to the substrate surface, and substantially all of this plane exists on a plane parallel to the substrate surface. The height of the three-dimensional element is 5 to 95%, preferably 10 to 90%, of the height h of the three-dimensional element before cutting the top. FIG. 3 is a top view of the polishing material of this embodiment.
[0046]
In FIG. 3, the symbol o indicates the base length of the three-dimensional element. The symbol u indicates the distance between the bottoms of the three-dimensional element. Symbol y indicates the length of one side of the top plane. o is, for example, 5 to 2000 μm, preferably 10 to 1000 μm. u is, for example, 0 to 1000 μm, preferably 2 to 500 μm. y is, for example, 0.5 to 1800 μm, preferably 1 to 900 μm.
[0047]
FIG. 4 is a cross-sectional perspective view of an abrasive material in which an abrasive layer according to another embodiment of the present invention has a three-dimensional structure. The polishing material 400 is a polishing material having a base material 401 and a polishing layer 402 provided on the surface of the base material.
[0048]
The polishing layer 402 has as a constituent a polishing composite that includes a binder matrix and abrasive grains 403 dispersed therein.
[0049]
The polishing layer 402 has a three-dimensional structure composed of three-dimensional elements 404 having a fixed shape arranged regularly. The three-dimensional element 404 has a prism shape in which a triangular prism is turned sideways. The apex angle β of the three-dimensional element 404 is usually 30 to 150 °, preferably 45 to 140 °.
[0050]
The top ridge of the three-dimensional element 404 exists on a plane parallel to the substrate surface over almost the entire area of the abrasive material. The symbol h in FIG. 4 indicates the height of the three-dimensional element from the substrate surface. h is usually 2 to 600 μm, preferably 4 to 300 μm. The variation in the height of the top line is preferably within 20% of the height of the three-dimensional element 404, and more preferably within 10%.
[0051]
Similarly to the three-dimensional element 104, the three-dimensional element 404 preferably has a two-layer structure of a top 405 made of an abrasive composite and a collar 406 made of a binder. In FIG. 4, the symbol s indicates the height of the top of the three-dimensional element. For example, s is 5 to 95%, preferably 10 to 90% of the height h of the three-dimensional element.
[0052]
In general, the three-dimensional elements 404 are arranged in stripes. In FIG. 4, the symbol w indicates the length of the short base of the three-dimensional element (the width of the three-dimensional element). The symbol p indicates the distance between the tops of the three-dimensional elements. The symbol u indicates the distance between the long bottom sides of the three-dimensional element. For example, w is 2 to 2000 μm, preferably 4 to 1000 μm. p is, for example, 2 to 4000 μm, preferably 4 to 2000 μm. u is, for example, 0 to 2000 μm, preferably 0 to 1000 μm.
[0053]
The length of the solid element 404 may be extended over substantially the entire area of the abrasive material. Or you may interrupt by appropriate length. The ends may or may not be aligned. The end of the prism-shaped three-dimensional element may be cut from the bottom with an acute angle so that a sloped ridge shape is formed in all directions. FIG. 5 is a top view of the polishing material of this embodiment.
[0054]
In FIG. 5, the symbol l indicates the long base length of the three-dimensional element. The symbol v indicates the distance cut with an acute angle of the three-dimensional element. The symbol x indicates the distance between the short base sides of the three-dimensional element. Signs w, p, and u have the same meaning as in FIG. l is, for example, 5 to 10,000 μm, preferably 10 to 5000 μm. v is, for example, 0 to 2000 μm, preferably 1 to 1000 μm. x is, for example, 0 to 2000 μm, preferably 0 to 1000 μm. For example, w is 2 to 2000 μm, preferably 4 to 1000 μm. p is, for example, 2 to 4000 μm, preferably 4 to 2000 μm. u is, for example, 0 to 2000 μm, preferably 0 to 1000 μm.
[0055]
The polishing material in which the polishing layer of the present invention illustrated in FIGS. 1 to 5 has a three-dimensional structure is particularly suitable for use in polishing an end face of an optical fiber connector, and can provide an end face of an optical fiber connector having extremely low connection loss characteristics. For example, the polishing material in which the polishing layer of the present invention has a three-dimensional structure provides an optical fiber connector end face with a connection loss of 1.0 dB or less, and further 0.5 dB or less.
[0056]
The abrasive material of the present invention is preferably produced by the method described below.
[0057]
First, an abrasive coating solution containing abrasive grains, a binder, and a solvent is prepared. The abrasive coating solution used here contains a sufficient amount of binder, abrasive grains and, if necessary, additives such as a photoinitiator to form a polishing composite, and imparts fluidity to this mixture. A composition further containing a sufficient amount of a volatile solvent. Even when the content of abrasive grains in the abrasive composite exceeds the critical pigment volume concentration, the fluidity can be maintained by incorporating a volatile solvent in the abrasive coating liquid.
[0058]
Preferred volatile solvents are organic solvents that dissolve the binder and are volatile at room temperature to 170 ° C. Specific examples include methyl ethyl ketone, methyl isobutyl ketone, toluene, xylene, ethanol, isopropyl alcohol, ethyl acetate, butyl acetate, tetrahydrofuran, propylene glycol monomethyl ether, propylene glycol monomethyl ether acetate and the like. A preferred solvent is water.
[0059]
Next, a mold sheet having a plurality of regularly arranged bottom side taper-shaped concave portions is prepared. The shape of the recess may be a shape obtained by inverting the solid element to be formed. As the material of the mold sheet, for example, a metal such as nickel, a plastic such as polypropylene, or the like may be used. For example, a thermoplastic resin such as polypropylene is preferable because it can be embossed on a metal tool at the melting temperature, so that a recess having a predetermined shape can be easily formed. When the binder is a radiation curable resin, it is preferable to use a material that transmits ultraviolet rays or visible rays. FIG. 6 is a process diagram schematically showing an example of a method for producing a polishing material in which the polishing layer has a three-dimensional structure.
[0060]
As shown in FIG. 6A, the obtained mold sheet 601 is filled with an abrasive coating liquid 602. The filling amount is sufficient to form the tops 105, 405 after the solvent is evaporated and the binder is cured. In general, after evaporating the solvent, it is sufficient to fill with an amount such that the depth from the bottom becomes the dimension of s shown in FIGS.
[0061]
Filling can be performed by applying the abrasive coating solution to the mold sheet with a coating device such as a roll coater. The viscosity of the abrasive coating solution during coating is 10 to 10⁶cps, especially 100-10^FiveIt is preferable to prepare to cps.
[0062]
As shown in FIG. 6B, the solvent is removed by evaporation from the filled abrasive coating solution. At that time, the mold sheet filled with the abrasive coating solution is generally heated to 50 to 150 ° C. Heating is performed for 0.2 to 10 minutes. When the binder is a thermosetting resin, the curing step may be performed simultaneously by heating at the curing temperature. When the volatility of the solvent is high, it may be left at room temperature for several minutes to several hours.
[0063]
As shown in FIG. 6C, the mold sheet is further filled with a laminating binder 603 to fill the recesses with the binder. The laminating binder may be the same as or different from that used in the abrasive coating solution. A binder having good adhesion to the substrate is preferred as the binder for laminating.
[0064]
Preferable binders for laminating are acrylate resins, epoxy resins, and urethane resins. The laminating binder may be filled by the same method as the abrasive coating solution.
[0065]
As shown in FIG. 6D, the base material 604 is overlapped on the mold sheet 601, and the binder is adhered to the base material. Adhesion is performed by, for example, pressing and laminating with a roll.
[0066]
The binder is cured. As used herein, the term “curing” means polymerizing to a solid state. The specific shape of the polishing layer does not change after curing. Curing may be performed separately or simultaneously for the binder of the abrasive coating solution and the laminating binder filled later alone.
[0067]
The binder is cured by heat, infrared irradiation or other irradiation energy such as electron beam irradiation, ultraviolet irradiation or visible light irradiation. The amount of irradiation energy applied varies depending on the type of binder used and the irradiation energy source. Usually, those skilled in the art can appropriately determine the amount of irradiation energy applied. The time required for curing varies depending on the thickness, density, temperature, and composition characteristics of the binder.
[0068]
For example, the binder may be cured by irradiating ultraviolet rays (UV) from above the transparent substrate.
[0069]
As shown in FIG. 6E, by removing the mold sheet, an abrasive material 606 composed of a base material 604 and an abrasive layer 605 having a three-dimensional structure is obtained. The binder may be cured after removing the mold sheet.
[0070]
【Example】
The following examples further illustrate the present invention, but the present invention is not limited thereto.
[0071]
Example 1
An abrasive coating solution was prepared by blending the components shown in Table 1.
[0072]
[Table 1]

Abrasive grain / binder ratio = 2.91
Abrasive grain / (binder + additive) ratio = 2.86
[0073]
A laminating binder was prepared by blending the components shown in Table 2.
[0074]
[Table 2]

[0075]
A polypropylene mold sheet having a recess having a shape obtained by inverting the three-dimensional element shown in FIG. 4 was prepared. The abrasive coating solution was applied to the mold sheet with a roll coater and dried at 50 ° C. for 5 minutes. On this, a laminating binder was applied, and a transparent polyester film having a thickness of 75 μm was layered thereon and laminated by applying pressure with a roll. Ultraviolet rays were irradiated from the polyester film side to cure the laminating binder. Next, the binder of the abrasive coating solution was cured by heating at 70 ° C. for 24 hours.
[0076]
The mold sheet was removed and cooled to room temperature to obtain an abrasive material. This polishing material has a prism-shaped three-dimensional structure in which the polishing layer is arranged in a stripe shape as shown in FIG. Each dimension is shown in Table 3.
[0077]
[Table 3]

[0078]
The abrasive material was punched into a circle having a diameter of 110 mm to produce an abrasive disk.
[0079]
The end face of the optical fiber connector was polished using the obtained polishing disk. Table 4 shows the polishing conditions.
[0080]
[Table 4]

[0081]
FIG. 7 shows the change over time in the cutting amount. After polishing, the end face of the optical fiber connector was observed with an electron microscope, and a smooth surface was confirmed. A photomicrograph is shown in FIG.
[0082]
Example 2
An abrasive coating solution was prepared by blending the components shown in Table 5.
[0083]
[Table 5]

Abrasive grain / binder ratio = 2.86
Abrasive grain / (binder + additive) ratio = 2.86
[0084]
A polishing disk was prepared in the same manner as in Example 1 except that this abrasive coating solution was used, and the end face of the optical fiber connector was polished. FIG. 7 shows the change over time in the cutting amount. After polishing, the end face of the optical fiber connector was observed with an electron microscope, and a smooth surface was confirmed. A photomicrograph is shown in FIG.
[0085]
Comparative Example 1
An abrasive material “Imperial diamond wrapping film 3 mil 3 micron type H” manufactured by Minnesota Mining and Manufacturing was punched into a circle having a diameter of 110 mm to produce an abrasive disc. The end face of the optical fiber connector was polished in the same manner as in Example 1 except that this polishing disk was used. FIG. 7 shows the change over time in the cutting amount. After polishing, the end face of the optical fiber connector was observed with an electron microscope, and a rough surface was confirmed. A photomicrograph is shown in FIG.
[0086]
Comparative Example 2
The abrasive coating solution prepared in Example 1 was applied to a polyester film having a thickness of 75 μm using a knife coater, and the solvent was removed by evaporation to form a polishing layer having a thickness of 11 μm. This polishing layer was heated at 70 ° C. for 24 hours to cure the binder. The obtained abrasive material was punched into a circle having a diameter of 110 mm to produce an abrasive disc.
[0087]
The end face of the optical fiber connector was polished in the same manner as in Example 1 except that this polishing disk was used. FIG. 7 shows the change over time in the cutting amount. After polishing, the end face of the optical fiber connector was observed with an electron microscope, and a rough surface was confirmed. A photomicrograph is shown in FIG.
[0088]
Comparative Example 3
The abrasive coating solution prepared in Example 2 was applied to a 75 μm thick polyester film using a knife coater, and the solvent was removed by evaporation to form an 11 μm thick polishing layer. This polishing layer was heated at 70 ° C. for 24 hours to cure the binder. The obtained abrasive material was punched into a circle having a diameter of 110 mm to produce an abrasive disc.
[0089]
The end face of the optical fiber connector was polished in the same manner as in Example 1 except that this polishing disk was used. FIG. 7 shows the change over time in the cutting amount. After polishing, the end face of the optical fiber connector was observed with an electron microscope, and a rough surface was confirmed. A photomicrograph is shown in FIG.
[0090]
Comparing FIGS. 8 and 9 with FIG. 10, it can be seen that the polishing materials of Examples 1 and 2 give a smoother polishing surface than the polishing material of Comparative Example 1 which is the current product. Further, comparing FIG. 8 with FIG. 11, the polishing material of Example 1 is more than the polishing material of Comparative Example 2 which is formed from the same abrasive coating solution but whose polishing layer does not have a three-dimensional structure. It can be seen that it gives a smooth polished surface. Comparing FIG. 9 with FIG. 12, the polishing material of Example 2 is formed from the same abrasive coating solution, but the polishing layer is smoother than the polishing material of Comparative Example 3 which is a polishing material having no three-dimensional structure. It turns out to give the surface.
[0091]
From the graph of FIG. 7, it can be seen that the polishing disk of Example 2 exhibits higher machinability than the polishing disks of Comparative Examples 1 to 3.
[0092]
Example 3
An abrasive coating solution was prepared by blending the components shown in Table 6.
[0093]
[Table 6]

Abrasive grain / binder ratio = 2.00
Abrasive grain / (binder + additive) ratio = 1.96
[0094]
The same polypropylene mold sheet as used in Example 1 was prepared. The abrasive coating solution was applied to the mold sheet with a roll coater and dried at 60 ° C. for 5 minutes. On this, the laminating binder prepared in Example 1 was applied, and a transparent polyester film having a thickness of 75 μm was layered thereon, and laminated by applying pressure with a roll. The binder was cured by irradiating ultraviolet rays from the polyester film side. The mold sheet was removed and cooled to room temperature to obtain an abrasive material. The abrasive material was punched into a circle having a diameter of 110 mm to produce an abrasive disk.
[0095]
On the other hand, an optical connector ferrule was prepared, and its end surface was polished with the same polishing conditions as in Table 7 using a polishing material “Imperial diamond wrapping film 3 mil 0.5 micron type H” manufactured by Minnesota Mining and Manufacturing. Polished with.
[0096]
Polishing was performed using the polishing disk on which the end face of the optical fiber connector was produced. Table 7 shows the polishing conditions.
[0097]
[Table 7]

[0098]
After polishing, the end face of the optical fiber connector was observed with an electron microscope, and a smooth surface was confirmed. A photomicrograph is shown in FIG.
[0099]
The shape of the polished end face of the optical fiber connector was measured with "ZOOM INTERFEROMETER ZX-1 MINI PMS" manufactured by Direct Optical Research Company (DORC), and the return loss was measured by JDS FITEL "Back". It was measured with a reflection meter RM300A. The results are shown in Table 9.
[0100]
Example 4
An abrasive coating solution was prepared by blending the components shown in Table 8.
[0101]
[Table 8]

Abrasive grain / binder ratio = 2.00
Abrasive grain / (binder + additive) ratio = 1.96
[0102]
A polishing disk was prepared and the end face of the optical fiber connector was polished in the same manner as in Example 3 except that this abrasive coating solution was used. FIG. 14 shows a photomicrograph of the end face after polishing. Table 9 shows the end face shape and the return loss.
[0103]
Comparative Example 4
An abrasive material “Imperial diamond wrapping film 3 mil 0.05 micron AO type P” manufactured by Minnesota Mining and Manufacturing was punched into a circle having a diameter of 110 mm to produce an abrasive disk. The end face of the optical fiber connector was polished in the same manner as in Example 3 except that this polishing disk was used. A photomicrograph of the end face after polishing is shown in FIG. Table 9 shows the end face shape and the return loss.
[0104]
Comparative Example 5
The abrasive coating solution prepared in Example 3 was applied to a polyester film having a thickness of 75 μm using a knife coater, and the solvent was removed by evaporation to form a polishing layer having a thickness of 4 μm. A 31 μm thick polyester film was laminated on the polishing layer, and the binder was cured by irradiating with ultraviolet rays. The obtained abrasive material was punched into a circle having a diameter of 110 mm to produce an abrasive disc.
[0105]
The end face of the optical fiber connector was polished in the same manner as in Example 3 except that this polishing disk was used. However, deposits accumulated on the end face during polishing, and polishing could not be performed effectively.
[0106]
Comparative Example 6
The abrasive coating solution prepared in Example 4 was applied to a polyester film having a thickness of 75 μm using a knife coater, and the solvent was removed by evaporation to form a polishing layer having a thickness of 4 μm. A 31 μm thick polyester film was laminated on the polishing layer, and the binder was cured by irradiating with ultraviolet rays. The obtained abrasive material was punched into a circle having a diameter of 110 mm to produce an abrasive disc.
[0107]
The end face of the optical fiber connector was polished in the same manner as in Example 3 except that this polishing disk was used. However, deposits accumulated on the end face during polishing, and polishing could not be performed effectively.
[0108]
[Table 9]

[0109]
As shown in FIGS. 13 and 14, when the polishing materials of Examples 3 and 4 were used, the polishing material “Imperial Diamond Wrapping Film 3 mil 0.5 by Minnesota Mining & Manufacturing Co., Ltd. Polishing marks (FIG. 10) generated by polishing with “micron type H” disappeared after 60 seconds of polishing. The end face of this optical fiber connector was finished very smoothly and finely, and as shown in Table 9, the return loss was also very small as compared with Comparative Example 4. The polishing material of Example 4 showed particularly good results when polishing was performed using 2-propanol as the cooling liquid.
[0110]
Example 5
An abrasive coating solution was prepared by blending the components shown in Table 10.
[0111]
[Table 10]

Abrasive grain / binder ratio = 2.72
Abrasive grain / (binder + additive) ratio = 2.69
[0112]
The same polypropylene mold sheet as used in Example 1 was prepared. The abrasive coating solution was applied to the mold sheet with a roll coater and dried at 70 ° C. for 5 minutes. On this, the laminating binder prepared in Example 1 was applied, and a transparent polyester film having a thickness of 75 μm was layered thereon, and laminated by applying pressure with a roll. The laminate binder was cured by irradiating ultraviolet rays from the polyester film side. Next, the binder of the abrasive coating solution was cured by heating at 70 ° C. for 24 hours.
[0113]
After cooling to room temperature, the mold sheet was removed to obtain an abrasive material. This abrasive material was punched into a circle having a diameter of 110 mm to produce an abrasive disc.
[0114]
A zirconia round bar (diameter 3 mm) was polished using the resulting polishing disk. Table 11 shows the polishing conditions.
[0115]
[Table 11]

[0116]
FIG. 16 shows the change over time in the cutting amount.
[0117]
Next, the polishing disk was replaced with a new one, and the end face of the optical fiber connector was polished. Table 12 shows the polishing conditions.
[0118]
[Table 12]

[0119]
After polishing, the end face of the optical fiber connector was observed with an electron microscope, and a smooth surface was confirmed. A photomicrograph is shown in FIG.
[0120]
Example 6
A polishing material was produced in the same manner as in Example 5 except that a polypropylene mold sheet having a concave portion having a shape obtained by inverting the three-dimensional element shown in FIG. This polishing material has a three-dimensional structure of a ridge shape in which the polishing layer is arranged in the stripe shape shown in FIG. Each dimension is shown in Table 13.
[0121]
[Table 13]

^*h is the height of the three-dimensional element, s is the height of the top of the three-dimensional element, and β is the apex angle shown in FIG.
[0122]
The obtained abrasive material was punched into a circle having a diameter of 110 mm to produce an abrasive disc. Using this polishing disk, the zirconia round bar and the end face of the optical fiber connector were polished in the same manner as in Example 5. FIG. 16 shows the change over time in the cutting amount of the zirconia round bar. When the end face of the optical fiber connector was observed with an electron microscope, a smooth surface was confirmed. A photomicrograph is shown in FIG.
[0123]
Example 7
A polishing material was produced in the same manner as in Example 5 except that a polypropylene mold sheet having a concave portion having a shape obtained by inverting the three-dimensional element shown in FIGS. 1 and 2 was used. This polishing material has a three-dimensional structure of a finely packed tetrahedral shape whose polishing layer is shown in FIGS. Table 14 shows the dimensions.
[0124]
[Table 14]

[0125]
The obtained abrasive material was punched into a circle having a diameter of 110 mm to produce an abrasive disc. Using this polishing disk, the zirconia round bar and the end face of the optical fiber connector were polished in the same manner as in Example 5. FIG. 16 shows the change over time in the cutting amount of the zirconia round bar. When the end face of the optical fiber connector was observed with an electron microscope, a smooth surface was confirmed. A photomicrograph is shown in FIG.
[0126]
Example 8
A polishing material was produced in the same manner as in Example 5 except that a polypropylene mold sheet having a concave portion having a shape obtained by inverting the three-dimensional element shown in FIG. 4 different from that used in Example 5 was used. This polishing material has a prism-shaped three-dimensional structure in which the polishing layer is arranged in a stripe shape as shown in FIG. Table 15 shows the dimensions.
[0127]
[Table 15]

[0128]
The obtained abrasive material was punched into a circle having a diameter of 110 mm to produce an abrasive disc. Using this polishing disk, the zirconia round bar and the end face of the optical fiber connector were polished in the same manner as in Example 5. FIG. 16 shows the change over time in the cutting amount of the zirconia round bar. When the end face of the optical fiber connector was observed with an electron microscope, a smooth surface was confirmed. A photomicrograph is shown in FIG.
[0129]
Comparative Example 7
An abrasive material “Imperial diamond wrapping film 3 mil 9 micron type H” manufactured by Minnesota Mining & Manufacturing was punched into a circle having a diameter of 110 mm to produce an abrasive disc. The zirconia round bar and the end face of the optical fiber connector were polished in the same manner as in Example 5 except that this polishing disk was used. FIG. 16 shows the change over time in the cutting amount of the zirconia round bar. When the end face of the optical fiber connector was observed with an electron microscope, a rough surface was confirmed. A photomicrograph is shown in FIG.
[0130]
Comparative Example 8
The abrasive coating solution prepared in Example 5 was applied to a polyester film having a thickness of 75 μm using a knife coater, and the solvent was removed by evaporation to form a polishing layer having a thickness of 14 μm. This polishing layer was heated at 70 ° C. for 24 hours, and further heated at 100 ° C. for 24 hours to cure the binder. The abrasive material obtained by cooling to room temperature was punched into a circle having a diameter of 110 mm to obtain an abrasive disc.
[0131]
A zirconia round bar and an optical fiber connector end face were polished in the same manner as in Example 6 except that this polishing disk was used. FIG. 16 shows the change over time in the cutting amount of the zirconia round bar. When the end face of the optical fiber connector was observed with an electron microscope, a rough surface was confirmed. A photomicrograph is shown in FIG.
[0132]
Example 9
An abrasive coating solution was prepared by blending the components shown in Table 16.
[0133]
[Table 16]

Abrasive grain / binder ratio = 2.86
Abrasive grain / (binder + additive) ratio = 2.82
[0134]
A laminating binder was prepared by blending the components shown in Table 17.
[0135]
[Table 17]

[0136]
The same polypropylene mold sheet as used in Example 1 was prepared. The abrasive coating solution was applied to the mold sheet with a roll coater and dried at 70 ° C. for 5 minutes. On this, a laminating binder was applied, and a transparent polyester film having a thickness of 75 μm was layered thereon and laminated by applying pressure with a roll. The laminate binder was cured by irradiating ultraviolet rays from the polyester film side. Next, the binder of the abrasive coating solution was cured by heating at 70 ° C. for 24 hours.
[0137]
The mold sheet was removed by cooling to room temperature, and further heated at 100 ° C. for 24 hours to cure the binder of the polishing layer. The abrasive material was punched into a circle having a diameter of 110 mm to produce an abrasive disk.
[0138]
A zirconia round bar and an optical fiber connector end face were polished in the same manner as in Example 5 except that the obtained polishing disk was used. FIG. 16 shows the change over time in the cutting amount of the zirconia round bar. When the end face of the optical fiber connector was observed with an electron microscope, a smooth surface was confirmed. A photomicrograph is shown in FIG.
[0139]
Example 10
A polishing material was produced in the same manner as in Example 9 except that the same polypropylene mold sheet as used in Example 6 was used. The abrasive material was punched into a circle having a diameter of 110 mm to produce an abrasive disk.
[0140]
A zirconia round bar and an optical fiber connector end face were polished in the same manner as in Example 5 except that the obtained polishing disk was used. FIG. 16 shows the change over time in the cutting amount of the zirconia round bar. When the end face of the optical fiber connector was observed with an electron microscope, a smooth surface was confirmed. A photomicrograph is shown in FIG.
[0141]
Example 11
A polishing material was produced in the same manner as in Example 9 except that a polypropylene mold sheet having a concave portion having a shape obtained by inverting the three-dimensional element shown in FIG. This polishing material has a three-dimensional structure of a pyramid shape in which the top of the polishing layer shown in FIG. 3 is cut at a predetermined height. Table 18 shows the dimensions.
[0142]
[Table 18]

^*h is the height of the three-dimensional element, s is the height of the top of the three-dimensional element, and α is the apex angle between the two ridges of the three-dimensional element before cutting the top.
[0143]
The obtained abrasive material was punched into a circle having a diameter of 110 mm to produce an abrasive disc. The zirconia round bar and the end face of the optical fiber connector were polished in the same manner as in Example 5 except that this polishing disk was used. FIG. 16 shows the change over time in the cutting amount of the zirconia round bar. When the end face of the optical fiber connector was observed with an electron microscope, a smooth surface was confirmed. A photomicrograph is shown in FIG.
[0144]
From the graph of FIG. 16, it can be seen that the abrasive disks of Examples 5 to 11 exhibit higher machinability and longer product life than the abrasive disks of Comparative Examples 7 and 8. Also, when FIGS. 17 to 20 and 23 to 25 are compared with FIGS. 21 and 22, the polishing disks of Examples 5 to 11 and the polishing disk of Comparative Example 7, which is the current product, and the polishing layer do not have a three-dimensional structure. It can be seen that a smoother polishing surface is provided than the polishing disk of Comparative Example 8.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a polishing material in which a polishing layer according to an embodiment of the present invention has a three-dimensional structure.
FIG. 2 is a top view of an abrasive material in which an abrasive layer according to an embodiment of the present invention has a three-dimensional structure.
FIG. 3 is a top view of an abrasive material in which an abrasive layer according to an embodiment of the present invention has a three-dimensional structure.
FIG. 4 is a cross-sectional perspective view of an abrasive material in which an abrasive layer according to an embodiment of the present invention has a three-dimensional structure.
FIG. 5 is a top view of an abrasive material in which an abrasive layer according to an embodiment of the present invention has a three-dimensional structure.
FIG. 6 is a process diagram schematically showing an example of a method for producing an abrasive material in which an abrasive layer has a three-dimensional structure.
FIG. 7 is a graph showing the change over time in the amount of cutting when the end face of the optical fiber connector is polished with various polishing materials.
FIG. 8 is a photomicrograph of the end face of an optical fiber connector after polishing with the polishing material of the present invention.
FIG. 9 is a photomicrograph of the end face of the optical fiber connector after polishing with the polishing material of the present invention.
FIG. 10 is a photomicrograph of an end face of an optical fiber connector after being polished with a conventional polishing material.
FIG. 11 is a photomicrograph of the end face of an optical fiber connector after polishing with a polishing material of the prior art.
FIG. 12 is a photomicrograph of an end face of an optical fiber connector after being polished with a conventional polishing material.
FIG. 13 is a photomicrograph of the end face of the optical fiber connector after polishing with the polishing material of the present invention.
FIG. 14 is a photomicrograph of an end face of an optical fiber connector after being polished with the polishing material of the present invention.
FIG. 15 is a photomicrograph of the end face of an optical fiber connector after polishing with a polishing material of the prior art.
FIG. 16 is a graph showing the change over time in the amount of cutting when a zirconia round bar is polished with various polishing materials.
FIG. 17 is a photomicrograph of the end face of the optical fiber connector after polishing with the polishing material of the present invention.
FIG. 18 is a photomicrograph of the end face of an optical fiber connector after polishing with the polishing material of the present invention.
FIG. 19 is a photomicrograph of the end face of the optical fiber connector after polishing with the polishing material of the present invention.
FIG. 20 is a photomicrograph of the end face of the optical fiber connector after being polished with the polishing material of the present invention.
FIG. 21 is a photomicrograph of the end face of an optical fiber connector after polishing with a polishing material of the prior art.
FIG. 22 is a photomicrograph of the end face of an optical fiber connector after polishing with a conventional polishing material.
FIG. 23 is a photomicrograph of the end face of the optical fiber connector after polishing with the polishing material of the present invention.
FIG. 24 is a photomicrograph of the end face of the optical fiber connector after polishing with the polishing material of the present invention.
FIG. 25 is a photomicrograph of the end face of the optical fiber connector after polishing with the polishing material of the present invention.
[Explanation of symbols]
100, 400 ... abrasive material,
101, 401 ... base material,
102, 402 ... polishing layer,
103, 403 ... abrasive grains,
104, 404 solid elements.

Claims (8)

(1) A step of filling an abrasive coating liquid containing abrasive grains, a binder, and a solvent into a mold sheet having a plurality of concave portions regularly arranged to a predetermined depth;
(2) A step of evaporating and removing the solvent from the abrasive coating liquid filled in the recess;
(3) a step of further filling the concave portion with a laminating binder;
(4) a step of superimposing a base material on the mold sheet and adhering the binder to the base material; and (5) a step of curing the binder;
A method for producing an abrasive material, wherein the abrasive layer has a three-dimensional structure. The method of claim 1, wherein the laminating binder is cured by ultraviolet irradiation. The method according to claim 1 or 2, wherein the concentration of the abrasive grains contained in the polishing coating liquid obtained by evaporating the solvent exceeds the critical pigment volume concentration. The method according to claim 1 or 2, wherein the binder contained in the abrasive coating solution is cured by heat. A polishing material used for polishing the end face of an optical fiber connector into a predetermined shape,
The abrasive material has a substrate and a polishing layer provided on the substrate,
The polishing layer has (1) a top portion made of a polishing composite containing abrasive grains dispersed in a binder, and (2) a collar portion containing a binder, and the polishing layer comprises an ordered layer. to a polishing material having a three-dimensional structure composed of three-dimensional elements of the plurality arranged a predetermined shape,
A polishing material in which the concentration of abrasive grains contained in the top exceeds the critical pigment volume concentration. The abrasive material according to claim 5, wherein the shape of the three-dimensional element is a shape in which a triangular prism is turned sideways and has a top line parallel to the substrate surface at the top . The polishing material according to claim 5 or 6, wherein the abrasive grains have a size of 0.01 to 20 µm. A method for polishing an end face of an optical fiber connector, which is performed using the polishing material according to claim 5.

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