EP4121249A1 - Article abrasif - Google Patents

Article abrasif

Info

Publication number
EP4121249A1
EP4121249A1 EP21713142.4A EP21713142A EP4121249A1 EP 4121249 A1 EP4121249 A1 EP 4121249A1 EP 21713142 A EP21713142 A EP 21713142A EP 4121249 A1 EP4121249 A1 EP 4121249A1
Authority
EP
European Patent Office
Prior art keywords
abrasive
abrasive particles
fabric substrate
abrasive article
coating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP21713142.4A
Other languages
German (de)
English (en)
Inventor
Junting LI
Yuyang LIU
Moses M. David
Jaime A. Martinez
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
3M Innovative Properties Co
Original Assignee
3M Innovative Properties Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 3M Innovative Properties Co filed Critical 3M Innovative Properties Co
Publication of EP4121249A1 publication Critical patent/EP4121249A1/fr
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/001—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as supporting member
    • B24D3/002—Flexible supporting members, e.g. paper, woven, plastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
    • B24D18/0072—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using adhesives for bonding abrasive particles or grinding elements to a support, e.g. by gluing

Definitions

  • the loops serve as the loop-portion of a hook-and-loop attachment system for attachment to a tool.
  • Net type products are known to provide superior dust extraction and/or anti-loading properties, when used with substrates known to severely load traditional abrasives. However, cut and/or life performance are still lacking. Thus, there is a need for a net type product that provides enhanced cut and/or life performance while demonstrating superior dust extraction.
  • a disclosure relates to an abrasive article that includes a fabric substrate comprising strands forming first void spaces between the strands.
  • the fabric substrate comprising an abrasive side and an attachment side.
  • the abrasive article also includes a coating on the attachment side.
  • the abrasive article also includes a make layer joined to the fabric substrate on the abrasive side.
  • the abrasive article also includes abrasive particles joined to the make layer.
  • the abrasive article also includes a plurality of second void spaces extending through the make layer coinciding with first void spaces in the fabric substrate.
  • the coating on the fabric substrate is both hydrophobic and lipophobic.
  • the attachment side of the fabric substrate is substantially free of make layer.
  • FIG. 1 is a perspective view of an abrasive article according to one example of the present disclosure.
  • FIGS. 2 is a side cross-sectional view of abrasive articles according to various embodiments of the present disclosure.
  • FIG. 3 is a schematic showing the step-wise construction of abrasive articles according to various embodiments of the present disclosure.
  • FIGS. 4A-4I are side cross-sectional views of a portion of an abrasive article according to various embodiments of the present disclosure.
  • FIGS. 5-7 are side cross-sectional views of abrasive articles according to embodiments of the present disclosure.
  • FIG. 8 is a close-up view of an abrasive article made with heat activated adhesive according to embodiments of the present disclosure.
  • FIG. 9 is a schematic illustration of a method of making an abrasive article with heat activated adhesive according to embodiments of the present disclosure.
  • FIG. 10 is a method of making an abrasive article using heat activated adhesive according to embodiments of the present disclosure.
  • FIGS. 11A-11C illustrate steps in a method of making an abrasive article using heat activated adhesive according to embodiments of the present disclosure.
  • FIGS. 12A-12B illustrate close-up views of abrasive articles made with heat activated adhesive according to embodiments of the present disclosure.
  • FIGS. 13-15 illustrate examples of another method of making an abrasive article with shaped agglomerate abrasive structures according to embodiments of the present disclosure.
  • FIG. 16 illustrates a schematic of an abrasive article according to embodiments of the present disclosure.
  • FIGS. 17A-F illustrates coated abrasive articles according to embodiments of the present disclosure.
  • FIG. 18 illustrates a method of making coated abrasive articles according to embodiments of the present disclosure.
  • FIG 19 illustrates coated abrasive articles described in the Examples.
  • Embodiments described herein are directed to an abrasive article that not only retains the dust-extraction advantages of an abrasive on a net-type backing, but also demonstrates abrasive performance (cut and/or life) advantages of a conventional abrasive.
  • This combination of benefits is possible because the construction of the abrasive articles described herein allows for pattern-coating abrasive on a fabric backing to form well-defined areas of abrasive coating as well as open areas devoid of any abrasive coating.
  • the patterned abrasive area can therefore be designed independent of any pattern present on the fabric substrate, to optimize both abrasive performance and dust extraction.
  • Embodiments herein also apply to direct coating of abrasive articles, particularly net-type backed abrasive articles.
  • FIG. 1 is a perspective view of one example of an abrasive article referred to by the numeral 100.
  • the abrasive article 100 includes: a fabric substrate 110 comprising strands forming first void spaces 270 between the strands (see FIG. 2); and an abrasive layer 120 joined to the fabric substrate 110; abrasive particles joined to the resin; and a plurality of void spaces extending through the fabric substrate 110 and the abrasive layer.
  • the plurality of void spaces coinciding with void spaces in the fabric substrate 110 allow for an air flow through the article 100 at a rate of, e.g., at least 0.1 L/s (e.g.
  • FIG. 1 illustrates one example of an abrasive article with large void spaces, according to PCT Application with Ser. No. 2020/050984, filed on February 11, 2020, incorporated herein by reference. Said application discusses the benefits of a laminate, as illustrated in FIG. 1.
  • One such benefit of a laminate layer for a mesh backing is the prevention of bleed-through of the make resin to the attachment side of the abrasive article.
  • methods and articles described herein illustrate that bleed-through can be avoided without a laminate layer.
  • it is possible to prevent bleed-through by treating an attachment side of the mesh with a hydro-lipophobic treatment that can repel the make coat, allowing for a continuous surface to form on the abrasive side.
  • FIG. 1 shows a relatively simple pattern that can be created with the abrasive layers 120.
  • abrasive articles 100 having various patterns in the abrasive layer 120 are shown in PCT Application with Ser. No. 2020/050984, fded on February 11, 2020.
  • the abrasive layers 120 can comprise a plurality of pattern elements 121, which may or may not be repeated across the surface of the abrasive article 100.
  • Each pattern element 121 can be comprised of one or more sub-elements.
  • Different pattern elements 121 within the same abrasive article may be provided with the same or different abrasive particles 250 or other additives (for example, different abrasive grades, blends of abrasive particles 250, fdlers, grinding aids, etc.) as desired for a given application.
  • abrasive articles could take any form (for example, sheets or belts).
  • FIG. 2 shows a cross-section of an abrasive article referred to by the numeral
  • the abrasive article 100 includes: a fabric substrate 110 comprising strands 260 forming first void spaces 270 between the strands 260; a hydro-lipophobic coating 230 joined to the fabric substrate 110 on an attachment side of substrate 110.
  • a cured resin composition 240 e.g., the cured product of a phenolic resin
  • abrasive particles 250 joined to the cured resin composition 240
  • a plurality of second void spaces 280 extending through the coating and the make coat, coinciding with first void spaces 270 in the fabric substrate 110.
  • the abrasive particles 250 are at least partially embedded in the cured resin composition 240.
  • the term “at least partially embedded” generally means that at least a portion of an abrasive particle is embedded in the cured resin composition, such that, the abrasive particle is anchored in the cured resin composition.
  • abrasive particles 250 are coated in the form of a slurry composition.
  • Abrasive particles 250 can optionally be oriented by influence of a magnetic field prior to the resin 240A being cured. See, for example, commonly-owned PCT Pub. Nos.
  • abrasive particles 250 can optionally be placed using tools for controlled orientation and placement of abrasive particles. See, for example, commonly- owned PCT Pub. Nos.
  • the abrasive article 100 comprises a first side
  • the second side 212 can include one part of a two-part hook and loop attachment system 213.
  • the first side can include the abrasive particles within or embedded on a make resin layer. Bleed-through is prevented, in some embodiments, by coating the first side with a hydro-lipophobic coating layer that prevents the make resin from bleeding through, as discussed in greater detail below.
  • FIG. 3 shows an example of one method by which the abrasive article 100 shown in FIG. 1 can be constructed in step-wise fashion.
  • a hydro-lipophobic coating layer is applied to fabric substrate
  • the hydro-lipophobic coating can be applied to the fabric substrate 110 by any suitable means, including a plasma treatment, a spray coating, or a foam, such as a fluoro-chemical based foam.
  • uncured resin composition 240A is joined to the fabric substrate 110 on a side opposite the hydro-lipophobic coating layer.
  • the uncured resin composition 240A can be applied in any suitable method including by using a (rotary) stencil/screen printing roll, flatbed screen/stencil printing or by directly printing the uncured resin composition 240A onto the fabric substrate or by using combinations of two or more suitable methods (e.g., extrusion die coating, curtain coating, knife coating, gravure coating, and spray coating) for joining the uncured resin composition 240A to the fabric substrate 110
  • abrasive particles 250 are joined to the uncured resin composition 240A by any suitable method, including drop, pattern electrostatic, magnetic, and other mechanical methods of mineral coating.
  • abrasive particles 250 can be deposited onto uncured resin composition 240A by simply dropping the abrasive particles 250 onto the uncured resin composition 240A; by electrostatically depositing abrasive particles 250 onto the uncured resin composition 240A; or by using combinations of two or more suitable methods for joining the abrasive particles 250 to the uncured resin composition 240A.
  • the abrasive particles 250 can optionally be oriented under the influence of a magnetic field prior to the resin 240A being cured, as earlier indicated.
  • the abrasive particles 250 may also be pattern coated on the uncured or partially cured resin composition.
  • the uncured resin composition 240A is cured, this way abrasive particles 250 are at least partially embedded in the cured resin composition 240 and are substantially permanently attached.
  • Uncured resin composition 240A can be cured to form cured resin 240 by any applicable curing mechanism, including thermal cure, photochemical cure, moisture-cured or combinations of two or more curing mechanism. But if the uncured resin composition 240A is cured by any means that does not include heating, a fifth step (not shown) may be necessary to fully open the void spaces 270 between strands 260.
  • FIG. 3 shows an example of one method by which the abrasive article 100 shown in FIG. 1 can be constructed in step-wise fashion, methods are also contemplated where one or more of the steps described herein can be accomplished in a single step or wherein certain steps can be performed in an order different than what is shown in FIG. 3.
  • a coating 230 is applied to a first side of substrate 110.
  • First side may be an attachment side including, for example, one part of a hook and loop attachment system.
  • the coating may be a hydrophobic coating, for embodiments where the resin to be applied is a water-based resin.
  • the coating may be a lipophobic coating, for embodiments where the resin to be applied is an organic-based resin.
  • the hydro-lipophobic coating can be applied as a plasma treatment, for example.
  • the hydrophobic coating may include fluorinated compounds, in some embodiments.
  • the coating in some embodiments, is a low-surface-energy coating features both hydrophobic and lipophobic features.
  • the coating may be a fluorochemical coating, a silane coating, a silicone coating, or nano-surface treatment.
  • make resin is applied to a second side of the substrate.
  • Make resin may be pattern coated, as illustrated in FIG. 3.
  • step 3 abrasive particles 250 are coupled to the make resin.
  • FIGS. 4A-4I show the various permutations (not exhaustive) that can occur when the cured resin composition 240 is coated or otherwise migrates away from the first void spaces 270 between strands 260.
  • the cured resin 240 can at least partially wrap around the strands 260 to create second void spaces 280, thus leaving open the first void spaces 270 as shown in FIGS. 4B, 4D, 4F, 4G, 4H, and 41.
  • the resin composition 240 extends over only the strands 260, not over first void spaces 270.
  • the resin composition 240 can wrap around some stands 260 and not others, as shown in FIG. 41.
  • FIG. 5 shows one example of an abrasive article referred to by the numeral
  • FIG. 200 which incorporates all of the features shown in FIG. 1, which will not be discussed again for the sake of brevity, but also a size coat 510 having size coat void spaces 520, which coincide with second void spaces 280.
  • FIG. 6 shows one example of an abrasive article referred to by the numeral 300, which incorporates all of the features shown in FIG.5, which will not be discussed again for the sake of brevity, but also a supersize coat 610 having supersize coat void spaces 620, which coincide with size coat void spaces 520 and second void spaces 280.
  • the abrasive article of the various embodiments described herein include fabric substrate 110.
  • Fabric substrate 110 may be constructed from any of a number of materials known in the art for making coated abrasive articles. Although not necessarily so limited, fabric substrate 110 can have a thickness of at least 0.02 millimeters, at least 0.03 millimeters, 0.05 millimeters, 0.07 millimeters, or 0.1 millimeters.
  • the backing could have a thickness of up to 5 millimeters, up to 4 millimeters, up to 2.5 millimeters, up to 1.5 millimeters, or up to 0.4 millimeters.
  • Fabric substrate 110 can be flexible and has voids spaces (e.g., void spaces
  • fabric substrate 110 can be made from cloth (e.g., cloth made from fibers or yams comprising polyester, nylon, silk, cotton, and/or rayon, which may be woven, knit or stitch bonded) and scrim.
  • the fabric substrate 110 can comprise a loop backing.
  • the abrasive layer of the abrasive article of the various embodiments described herein is made from a curable composition (e.g., uncured or partially cured resin composition 240A).
  • a curable composition e.g., uncured or partially cured resin composition 240A
  • this specification makes reference to cured (e.g., cured resin composition 240) or uncured compositions (e.g., uncured or partially cured resin composition 240A), where the cured composition is synonymous with the abrasive layer 120.
  • the nature of the uncured or partially cured resin composition 240A that is converted to cured resin composition 240 is non-limiting, and can include, for example, any suitable additives or formulations described in PCT Application with Ser. No. IB2020/050984, filed February 7, 2020..
  • the curable compositions can contain one or more fiber reinforcement materials.
  • a fiber reinforcement material can provide an abrasive layer having improved cold flow properties, limited stretchability, and enhanced strength.
  • the one or more fiber reinforcement materials can have a certain degree of porosity that enables a photoinitiator, when present, to be dispersed throughout, to be activated by UV light, and properly cured without the need for heat. Further options and advantages of the fiber reinforcement materials are described in U.S. Patent Publication No. 2002/0182955 (Weglewski et ak).
  • FIGS. 8-12 illustrate another embodiment of the present invention in which a heat-activated adhesive is used to attach abrasive particles to a fiber backing.
  • FIG. 8 is a close-up view of an abrasive article made with heat activated adhesive according to embodiments of the present disclosure.
  • FIG. 8 illustrates a mesh abrasive 1100 with a mesh backing 1110 onto which a heat activated adhesive 1120 has been applied.
  • the heat activated adhesive can be applied on a nonwoven web and used to adhere abrasive particles without the use of an additional resin material.
  • an adhesive with a melting point above 170° is used.
  • adhesives with lower melting points can be used.
  • the adhesive should have a melting point high enough that the adhesive will not melt during use of an abrasive article.
  • FIG. 9 is a schematic illustration of a method of making an abrasive article with heat activated adhesive according to embodiments of the present disclosure.
  • Schematic images 1201 A and 1251A illustrate a side view of backing showing the loops as attached to a single fiber.
  • Schematic images 120 IB and 125 IB illustrate front views of three fibers in a mesh backing. While schematic images 1201 A-B and 1251 A-B illustrate only a few fibers 1230 for ease of understanding, it is understood that the concept applies to larger arrangements of fibers 1230.
  • a plurality of fibers 1230, each with one or more attached loops 1220, can be coated with a heat activated adhesive 1240.
  • a heat activated adhesive film 1240 is laminated to fibers 1230.
  • Adhesive film 1240 can be heated to a melting temperature, to ensure adhesion to fibers 1230, and cooled back down to room temperature.
  • Abrasive particles 1210 can be applied to adhesive film 1240.
  • abrasive particles 1210 may be heated to a temperature high enough to soften adhesive film 1240, allowing abrasive particles 1210 to embed within adhesive layer 1240, as illustrated in schematic images 1251A and 125 IB.
  • Adhesive particles that do not attach to adhesive layer 1240 may fall through the voids in the fiber backing, as illustrated in FIG. 125 IB.
  • crushed abrasive particles are illustrated in FIG. 9, it is expressly contemplated that the method illustrated can be applied to other abrasive particles, such as platey, formed, shaped, or partially shaped particles.
  • FIG. 10 is a method of making an abrasive article using heat activated adhesive according to embodiments of the present disclosure.
  • Method 1300 may be useful for making abrasive articles.
  • a heat activated adhesive is applied to a backing.
  • the backing is a mesh backing.
  • Applying a heat activated adhesive to a backing can include laminating the adhesive as a film, as indicated in block 1302, or directly coating the adhesive, as indicated in block 1304, or roll-coating the adhesive, as indicated in block 1306. Other application methods may also be used, as indicated in block 1308. Applying a heat-activated adhesive to a backing may also involve first heating the adhesive layer, as indivated in block 312, and then cooling the adhesive layer, as indicated in block 314.
  • abrasive grains are applied to the adhesive backing. Applying adhesive grains to the adhesive layer can include drop-coating methods, as indicated in block 1322, using a transfer tool, as indicated in block 1324, or other methods, as indicated in block 1326. For example, magnetically coated abrasive particles may be aligned on an adhesive-coated backing by applying a magnetic force. Additionally, abrasive particles may be coated using electrostatic forces.
  • the abrasive grains can be embedded into the adhesive layer by partially melting the heat-activated adhesive. This can be done by pre-heating the abrasive grains to a temperature higher than the melting point of the heat-activated adhesive, as indicated in block 1327.
  • the potential cooling of the abrasive particles during transfer to the adhesive should be considered. Therefore, in some embodiments, the abrasive grains are heated to a temperature several degrees higher than the melting point to allow for cooling during the coating process.
  • the adhesive-coated backing can be heated, either in addition to or as an alternative to heating the abrasive particles, as indicated in block 1328.
  • additives are applied.
  • multiple types of abrasive grains can be applied to the adhesive layer, as indicated in block 1332.
  • both precision shaped grains and crushed grains may be adhered to the adhesive layer.
  • two different sizes of precision shaped grains may be applied to the adhesive layer.
  • Additional functional layers may also be applied over the adhered abrasive grains, such as a size coat, as indicated in block 1334, or a supersize coat, as indicated in block 1336. Additional layers may also be included, as indicated in block 1338, such as agrinding aid or lubrication aid.
  • FIGS. 11A-11C illustrate steps in a method of making an abrasive article using heat activated adhesive according to embodiments of the present disclosure.
  • FIG. 11A illustrates a mesh backing 1400 with a plurality of fibers 1410.
  • FIG. 1 IB illustrates a mesh backing 1450 where a heat activated adhesive 1420 has been applied to portions of fibers 1410 of mesh backing 1450.
  • FIG. 11C illustrates a mesh backing 1480 coated with precision-shaped abrasive particles 1430.
  • the precision-shaped particles 1430 of FIG. 11C are triangle-shaped, however other shapes are also expressly envisioned for other embodiments.
  • FIGS. 12A-12B illustrate close-up views of abrasive articles made with heat activated adhesive according to embodiments of the present disclosure.
  • FIG. 12A illustrates a view of amesh backing coated with P100 aluminum-zirconia abrasive particles.
  • FIG. 12B illustrates a mesh backing coated with precision-shaped grain that was applied by heating the mesh backing to 155°C before drop-coating the particles.
  • the particles instead of or in addition to the mesh backing, could be pre heated before application.
  • abrasive particles may be utilized in the various embodiments described herein.
  • the particular type of abrasive particle e.g. size, shape, chemical composition
  • Suitable abrasive particles may be formed of, for example, cubic boron nitride, zirconia, alumina, silicon carbide and diamond.
  • the abrasive particles may be provided in a variety of sizes, shapes and profiles, including, for example, random or crushed shapes, regular (e.g. symmetric) profiles such as square, star-shaped or hexagonal profiles, and irregular (e.g. asymmetric) profiles.
  • the abrasive article may include a mixture of abrasive particles that are inclined on the backing (i.e. stand upright and extend outwardly from the backing) as well as abrasive particles that lie flat on their side (i.e. they do not stand upright and extend outwardly from the backing).
  • the abrasive article may include a mixture of different types of abrasive particles.
  • the abrasive article may include mixtures of platey and non-platey particles, crushed, agglomerated, and shaped particles (which may be discrete abrasive particles that do not contain a binder or agglomerate abrasive particles that contain a binder), conventional non-shaped and non-platey abrasive particles (e.g. filler material) and abrasive particles of different sizes.
  • FIGS. 13A-13D illustrate abrasive agglomerate particles on a mesh backing.
  • an agglomerate abrasive particle 1700 includes abrasive grains 1710 and can have one or more agglomerate shape features.
  • Agglomerate abrasive particle 1700, as illustrated in FIG. 13 A, may also include a second type of abrasive particle 1720.
  • abrasive agglomerate 1700 can be defined as having a width, w, a thickness, h, with a ratio of w/h being higher than 2. In a preferred embodiment, the width is higher than 5. In some embodiments, the width of the agglomerate is larger than 1000 pm.
  • the abrasive agglomerates, as illustrated in FIGS. 13A-13D may be at least partially precisely shaped.
  • the shapes may include, but are not limited to, nonagon, octagon, heptagon, hexagon, triangle (scalene, acute, obtuse, isosceles, equilateral, or right), parallelogram, rhombus, rectangle, square, pentagon, circle, oval, heart, cross, arrow, star (with any number of points from 3, as illustrated in FIG. 13 A, to 10), or crescent.
  • Abrasive agglomerate particles such as those illustrated in FIGS. 13A-13D may be especially useful for making mesh abrasive articles. As illustrated in FIG. 13B, at least one dimension of the abrasive particle 1700 is greater than the gaps in mesh backing 1750, ensuring that abrasive agglomerates do not fall through the mesh backing.
  • abrasive agglomerate particles 1760 may comprise abrasive particles 1764 within a resin bond 1762.
  • the abrasive agglomerate particles may be placed on a backing 1750 in a pattern, or dropped in a random configuration. This can give the benefit of a ‘patterned’ abrasive structure, as each individual agglomerate has a shape, but also the benefits of random placement, which may reduce scratches or cut patterns on an abraded worksurface. Additionally, systems and methods herein can also apply to direct coating methods of abrasives and resins.
  • FIG. 14 illustrates one schematic method of making a mesh abrasive article with agglomerate abrasive particles.
  • the agglomerates 1830 may be premade, for example, using methods of making agglomerates described in U.S. PAP 2019/0283216, published on September 19, 2019 and U.S. PAP 2017/058254 (describing vitrified shaped agglomerates), and PCT Publication WO 2019/0167022, published September 6, 2019 (describing siliceous bond agglomerates), as well as US PAP 2019/0270922, published September 5, 2019, all of which are incorporated herein by reference.
  • the agglomerates may proceed, as indicated in direction 1850, on a conveyance mechanism 1840.
  • a horizontal conveyance mechanism 1840 is illustrated, it is expressly contemplated that a tilted conveyance mechanism 1840, or other suitable deposition mechanisms, such as a drop coater or other suitable mechanism for depositing the agglomerates 1830 in a pattern or random configuration.
  • a backing 1810 proceeds, also in direction 1850 in one embodiment, on a conveyance mechanism.
  • Backing 1810 may have a make coat 1820 applied such that deposited abrasive agglomerates 1830.
  • Make coat 1820 may include a make resin, a blown melty film, or a hot melt adhesive, for example.
  • FIGS. 15A and 15B illustrate linear abrasive agglomerates that may also be useful in mesh abrasive article formation.
  • the linear abrasive agglomerate has at least one dimension that is longer than a gap between mesh fibers, ensuring that the abrasive agglomerate will adhere to a make resin layer on the abrasive article.
  • Suitable shaped abrasive particles can be found in, for example,
  • a material from which the shaped abrasive particles may be formed comprises alpha alumina.
  • Alpha alumina shaped abrasive particles can be made from a dispersion of aluminum oxide monohydrate that is gelled, molded to shape, dried to retain the shape, calcined, and sintered according to techniques known in the art.
  • Published U.S. Appl. No. 2015/0267097 which is incorporated herein by reference. Published U.S. Appl. No. 2015/0267097 generally describes abrasive particles comprising alpha alumina having an average crystal grain size of 0.8 to 8 microns and an apparent density that is at least 92 percent of the true density. Each shaped abrasive particle can have a respective surface comprising a plurality of smooth sides that form at least four vertexes. [0070]
  • U.S. Patent No. 8,034,137 (Erickson et al.) describes alumina abrasive particles that have been formed in a specific shape, then crushed to form shards that retain a portion of their original shape features.
  • shaped alpha alumina particles are precisely-shaped (i.e., the particles have shapes that are at least partially determined by the shapes of cavities in a production tool used to make them). Details concerning such shaped abrasive particles and methods for their preparation can be found, for example, in U.S. Patent Nos. 8,142,531 (Adefris et al.); 8,142,891 (Culler et al.); and 8,142,532 (Erickson etal.); and in U.S. Pat. Appl. Publ. Nos. 2012/0227333 (Adefris etal.); 2013/0040537 (Schwabel et al.); and 2013/0125477 (Adefris).
  • crushed abrasive particles include crushed abrasive particles comprising fused aluminum oxide, heat-treated aluminum oxide, white fused aluminum oxide, ceramic aluminum oxide materials such as those commercially available as 3M CERAMIC ABRASIVE GRAIN from 3M Company, St.
  • sol-gel-derived abrasive particles from which crushed abrasive particles can be isolated and methods for their preparation can be found in U.S. Patent Nos. 4,314,827 (Leitheiser et al.); 4,623,364 (Cottringer et al.); 4,744,802 (Schwabel), 4,770,671 (Monroe et al.); and 4,881,951 (Monroe et al.). It is also contemplated that the crushed abrasive particles could comprise abrasive agglomerates such as, for example, those described in U.S. Patent Nos.
  • the crushed abrasive particles comprise ceramic crushed abrasive particles such as, for example, sol-gel-derived polycrystalline alpha alumina particles. Ceramic crushed abrasive particles composed of crystallites of alpha alumina, magnesium alumina spinel, and a rare earth hexagonal aluminate may be prepared using sol-gel precursor alpha alumina particles according to methods described in, for example, U.S. Patent No. 5,213,591 (Celikkaya et al.) and U.S. Publ. Pat. Appln. Nos. 2009/0165394 Al (Culler et al.) and 2009/0169816 Al (Erickson et al.).
  • sol-gel-derived abrasive particles Further details concerning methods of making sol-gel-derived abrasive particles can be found in, for example, U.S. Patent Nos. 4,314,827 (Leitheiser); 5,152,917 (Pieper et al.); 5,435,816 (Spurgeon et al.); 5,672,097 (Hoopman et al.); 5,946,991 (Hoopman et al.); 5,975,987 (Hoopman et al.); and 6,129,540 (Hoopman et al.); and in U.S. Patent Publication No. 2009/0165394 Al (Culler etal.). Examples of suitable platey crushed abrasive particles can be found in, for example, U.S.
  • the abrasive particles may be surface-treated with a coupling agent (e.g., an organosilane coupling agent) or other physical treatment (e.g., iron oxide or titanium oxide) to enhance adhesion of the crushed abrasive particles to the binder.
  • a coupling agent e.g., an organosilane coupling agent
  • other physical treatment e.g., iron oxide or titanium oxide
  • the abrasive layer in some embodiments, includes a particulate mixture comprising a plurality of formed abrasive particles (e.g., precision shaped grain (PSG) mineral particles available from 3M, St. Paul, MN, which are described in greater detail herein; not shown in FIGS. 1-3) and a plurality of abrasive particles 250, or only formed abrasive particles, adhesively secured to the abrasive layer.
  • a plurality of formed abrasive particles e.g., precision shaped grain (PSG) mineral particles available from 3M, St. Paul, MN, which are described in greater detail herein; not shown in FIGS. 1-3
  • PSG precision shaped grain
  • the abrasive particles may be formed abrasive particles.
  • the term “formed abrasive particles” generally refers to abrasive particles (e.g., formed ceramic abrasive particles) having at least a partially replicated shape.
  • Non-limiting examples of formed abrasive particles are disclosed in Published U.S. Patent Appl. No. 2013/0344786, which is incorporated by reference as if fully set forth herein.
  • Non-limiting examples of formed abrasive particles include shaped abrasive particles formed in a mold, such as triangular plates as disclosed in U.S. Pat. Nos.
  • Formed abrasive particles also include shaped abrasive particles.
  • shaped abrasive particle generally refers to abrasive particles with at least a portion of the abrasive particles having a predetermined shape that is replicated from a mold cavity used to form the shaped precursor abrasive particle. Except in the case of abrasive shards (e.g. as described in U.S. patent publication US 2009/0169816), the shaped abrasive particle will generally have a predetermined geometric shape that substantially replicates the mold cavity that was used to form the shaped abrasive particle.
  • Shaped abrasive particle as used herein excludes randomly sized abrasive particles obtained by a mechanical crushing operation.
  • Formed abrasive particles also include precision-shaped grain (PSG) mineral particles, such as those described in Published U.S. Appl. No. 2015/267097, which is incorporated by reference as if fully set forth herein.
  • PSG precision-shaped grain
  • Suitable abrasive particles include, for example, fused aluminum oxide, heat treated aluminum oxide, white fused aluminum oxide, black silicon carbide, green silicon carbide, titanium diboride, boron carbide, silicon nitride, tungsten carbide, titanium carbide, diamond, cubic boron nitride, hexagonal boron nitride, garnet, fused alumina zirconia, alumina-based sol gel derived abrasive particles, silica, iron oxide, chromia, ceria, zirconia, titania, tin oxide, gamma alumina, and mixtures thereof.
  • the alumina abrasive particles may contain a metal oxide modifier.
  • the diamond and cubic boron nitride abrasive particles may be monocrystalline or poly crystalline.
  • the formed abrasive particles have a substantially monodisperse particle size of from about 1 micrometers to about 5000 micrometers, from about 1 micrometers to about 2500, from about 1 micrometers to about 1000, from about 10 micrometers to about 5000, from about 10 micrometers to about 2500, from about 10 micrometers to about 1000, from about 50 micrometers to about 5000, from about 50 micrometers to about 2500, from about 50 micrometers to about 1000.
  • substantially monodisperse particle size is used to describe formed abrasive particles having a size that does not vary substantially.
  • formed abrasive particles e.g., a PSG mineral particles
  • greater than 90%, greater than 95% or greater than 99% of the formed abrasive particles will have a particle having its largest dimension be 100 micrometers.
  • the abrasive particles can have a range or distribution of particle sizes. Such a distribution can be characterized by its median particle size.
  • the median particle size of the abrasive particles may be at least 0.001 micrometers, at least 0.005 micrometers, at least 0.01 micrometers, at least 0.015 micrometers, or at least 0.02 micrometers.
  • the median particle size of the abrasive particles may be up to 300 micrometers, up to 275 micrometers, up to 250 micrometers, up to 150 micrometers, or up to 100 micrometers.
  • the median particle size of the abrasive particles is from about 1 micrometers to about 600 micrometers, from about 1 micrometers to about 300 micrometers, from about 1 micrometers to about 150 micrometers, from about 10 micrometers to about 600 micrometers, from about 10 micrometers to about 300 micrometers, from about 10 micrometers to about 150 micrometers, from about 50 micrometers to about 600 micrometers, from about 50 micrometers to about 300 micrometers, from about 50 micrometers to about 150 micrometers.
  • the abrasive particle of the present disclosure may include formed abrasive particles.
  • the formed abrasive particles may be present from 0.01 wt. percent to 100 wt, percent, from 0.1 wt. percent to 100 wt, percent, from 1 wt. percent to 100 wt, from 10 wt. percent to 100 wt, percent, from 0.01 wt. percent to 90 wt, percent, from 0.1 wt. percent to 90 wt, percent, from 1 wt. percent to 90 wt, from 10 wt. percent to 90 wt, percent, from 0.01 wt. percent to 75 wt, percent, from 0.1 wt. percent to 75 wt, percent, from 1 wt. percent to 75 wt, from 10 wt. percent to 75 wt, percent, based on the total weight of the abrasive particles.
  • the particulate mixture comprises from about greater than
  • abrasive particles e.g., from about 91 wt.% to about 97 wt.%; about 92 wt.% to about 97 wt.%; about 95 wt.% to about 97 wt.%; or greater than about 90 wt.% to about 97 wt.%).
  • the abrasive article of the various embodiments described herein include a size coat 510. See FIG. 5.
  • the size coat comprises the cured product of a phenolic size composition.
  • the size coat comprises the cured (e.g., photopolymerized) product of a bis-epoxide (e.g., 3,4-epoxy cyclohexylmethyl-3 ,4-epoxy cyclohexylcarboxylate, available from Daicel Chemical Industries, Ltd., Tokyo, Japan); a trifunctional acrylate (e.g., trimethylol propane triacrylate, available under the trade designation “SR351” from Sartomer USA, LLC, Exton, PA); an acidic polyester dispersing agent (e.g., “BYK W-985” from Byk-Chemie, GmbH, Wesel, Germany); a filler (e.g., a sodium-potassium alumina silicate filler, obtained under the
  • the abrasive article of the various embodiments described include a supersize coat 610. See FIG. 6.
  • the supersize coat is the outermost coating of the abrasive article and directly contacts the workpiece during an abrading operation.
  • the supersize coat is, in some examples, substantially transparent.
  • substantially transparent refers to a majority of, or mostly, as in at least about 30%, 40%, 50%, 60%, or at least about 70% or more transparent.
  • the measure of the transparency of any given coat described herein is the coat’s transmittance.
  • the supersize coat displays a transmittance of at least 5 percent, at least 20 percent, at least 40 percent, at least 50 percent, or at least 60 percent (e.g., a transmittance from about 40 percent to about 80 percent; about 50 percent to about 70 percent; about 40 percent to about 70 percent; or about 50 percent to about 70 percent), according to a Transmittance Test that measures the transmittance of 500 nm light through a sample of 6 by 12 inch by approximately 1-2 mil (15.24 by 30.48 cm by 25.4 - 50.8 pm) clear polyester film, having a transmittance of about 98%.
  • a Transmittance Test that measures the transmittance of 500 nm light through a sample of 6 by 12 inch by approximately 1-2 mil (15.24 by 30.48 cm by 25.4 - 50.8 pm) clear polyester film, having a transmittance of about 98%.
  • One component of supersize coats can be a metal salt of a long-chain fatty acid (e.g., a C12-C22 fatty acid, a C14-C18 fatty acid, and a C16-C20 fatty acid).
  • the metal salt of a long-chain fatty acid is a stearate salt (e.g., a salt of stearic acid).
  • the conjugate base of stearic acid is C17H35COO-, also known as the stearate anion.
  • Useful stearates include, but are not limited to, calcium stearate, zinc stearate, and combinations thereof.
  • the metal salt of a long-chain fatty acid can be present in an amount of at least 10 percent, at least 50 percent, at least 70 percent, at least 80 percent, or at least 90 percent by weight based on the normalized weight of the supersize coat (i.e., the average weight for a unit surface area of the abrasive article).
  • the metal salt of a long -chain fatty acid can be present in an amount of up to 100 percent, up to 99 percent, up to 98 percent, up to 97 percent, up to 95 percent, up to 90 percent, up to 80 percent, or up to 60 percent by weight (e.g., from about 10 wt.% to about 100 wt.%; about 30 wt.% to about 70 wt.%; about 50 wt.% to about 90 wt.%; or about 50 wt.% to about 100 wt.%) based on the normalized weight of the supersize coat.
  • the supersize coat is a polymeric binder, which, in some examples, enables the supersize coat to form a smooth and continuous fdm over the abrasive layer.
  • the polymeric binder is a styrene-acrylic polymer binder.
  • the styrene-acrylic polymer binder is the ammonium salt of a modified styrene -acrylic polymer, such as, but not limited to, JONCRYL® LMV 7051.
  • the ammonium salt of a styrene-acrylic polymer can have, for example, a weight average molecular weight (Mw) of at least 100,000 g/mol, at least 150,000 g/mol, at least 200,000 g/mol, or at least 250,000 g/mol (e.g., from about 100,000 g/mol to about 2.5 x 106 g/mol; about 100,000 g/mol to about 500,000 g/mol; or about 250,000 to about 2.5 x 106 g/mol).
  • Mw weight average molecular weight
  • the minimum film-forming temperature also referred to as MFFT, is the lowest temperature at which a polymer self-coalesces in a semi-dry state to form a continuous polymer film.
  • this polymer film can then function as a binder for the remaining solids present in the supersize coat.
  • the styrene-acrylic polymer binder e.g., the ammonium salt of a styrene -acrylic polymer
  • the binder is dried at relatively low temperatures (e.g., at
  • the drying temperatures are, in some examples, below the melting temperature of the metal salt of a long-chain fatty acid component of the supersize coat.
  • Use of excessively high temperatures (e.g., temperatures above 80°C) to dry the supersize coat is undesirable because it can induce brittleness and cracking in the backing, complicate web handling, and increase manufacturing costs.
  • a binder comprised of, e.g., the ammonium salt of a styrene-acrylic polymer allows the supersize coat to achieve better fdm formation at lower binder levels and at lower temperatures without need for added surfactants such as DOWANOL® DPnP.
  • the polymeric binder can be present in an amount of at least 0.1 percent, at least 1 percent, or at least 3 percent by weight, based on the normalized weight of the supersize coat.
  • the polymeric binder can be present in an amount of up to 20 percent, up to 12 percent, up to 10 percent, or up to 8 percent by weight, based on the normalized weight of the supersize coat.
  • the ammonium salt of a modified styrene acrylic copolymer is used as a binder, the haziness normally associated with a stearate coating is substantially reduced.
  • the supersize coats of the present disclosure optionally contain clay particles dispersed in the supersize coat.
  • the clay particles when present, can be uniformly mixed with the metal salt of a long chain fatty acid, polymeric binder, and other components of the supersize composition.
  • the clay can bestow unique advantageous properties to the abrasive article, such as improved optical clarity and improved cut performance.
  • the inclusion of clay particles can also enable cut performance to be sustained for longer periods of time relative to supersize coats in which the clay additive is absent.
  • the clay particles when present, can be present in an amount of at least 0.01 percent, at least 0.05 percent, at least 0.1 percent, at least 0.15 percent, or at least 0.2 percent by weight based on the normalized weight of the supersize coat. Further, the clay particles can be present in an amount of up to 99 percent, up to 50 percent, up to 25 percent, up to 10 percent, or up to 5 percent by weight based on the normalized weight of the supersize coat. [0096] The clay particles may include particles of any known clay material.
  • Such clay materials include those in the geological classes of the smectites, kaolins, illites, chlorites, serpentines, attapulgites, palygorskites, vermiculites, glauconites, sepiolites, and mixed layer clays.
  • Smectites in particular include montmorillonite (e.g., a sodium montmorillonite or calcium montmorillonite), bentonite, pyrophyllite, hectorite, saponite, sauconite, nontronite, talc, beidellite, and volchonskoite.
  • kaolins include kaolinite, dickite, nacrite, antigorite, anauxite, halloysite, indellite and chrysotile.
  • Illites include bravaisite, muscovite, paragonite, phlogopite and biotite.
  • Chlorites can include, for example, corrensite, penninite, donbassite, sudoite, pennine and clinochlore.
  • Mixed layer clays can include allevardite and vermiculitebiotite. Variants and isomorphic substitutions of these layered clays may also be used.
  • nanoparticles i.e., nanoscale particles
  • Useful nanoparticles include, for example, nanoparticles of metal oxides, such as zirconia, titania, silica, ceria, alumina, iron oxide, vanadia, zinc oxide, antimony oxide, tin oxide, and alumina-silica.
  • the nanoparticles can have a median particle size of at least 1 nanometer, at least 1.5 nanometers, or at least 2 nanometers.
  • the median particle size can be up to 200 nanometers, up to 150 nanometers, up to 100 nanometers, up to 50 nanometers, or up to 30 nanometers.
  • compositions include curing agents, surfactants, antifoaming agents, biocides, and other particulate additives known in the art for use in supersize compositions.
  • the supersize coat can be formed, in some examples, by providing a supersize composition in which the components are dissolved or otherwise dispersed in a common solvent.
  • the solvent is water.
  • the supersize dispersion can be coated onto the underlying layers of the abrasive article and dried to provide the finished supersize coat.
  • the supersize composition can be cured (e.g., hardened) either thermally or by exposure to actinic radiation at suitable wavelengths to activate the curing agent.
  • the coating of the supersize composition onto, e.g., the abrasive layer can be carried out using any known process.
  • the supersize composition is applied by spray coating at a constant pressure to achieve a pre -determined coating weight.
  • a knife coating method where the coating thickness is controlled by the gap height of the knife coater can be used.
  • FIG. 16 illustrates schematic views of a strand 2020 within a coated abrasive article 2000.
  • a single strand 2020 has a make coat 2030 deposited on one side, to which abrasive particles 2040 are adhered.
  • a fabric substrate 202 has an attachment system, such as looks 2010, adhered to a side opposing the abrasive particles.
  • Abrasive articles can be made using fabric substrates with strands, such as strand 2020 of FIG. 16, in an open weave, with large openings separating adjoining strands. Applying a standard make resin 2030 is difficult on an open backing without complex coating equipment or process. Systems and methods are desired to allow placement of make resin 2030 on an open mesh backing 2020 using knife or roller coating.
  • a coating or treatment is applied to a backing of an abrasive article to induce partial, temporary, or permanent hydro- lipophobicity that can reduce the surface energy of the backside of the backing and prevent the make resin from wicking the backside of the backing and the sidewalls of individual strands within the backing.
  • Hydrophobicity is desired for make resins that are at least partially aqueous in nature.
  • Lipophobic is desired for make resins that are at least partially lipid in nature.
  • a hydro-lipophobic coating can be applied using a variety of materials, including, for example, tetramethylsilane, titanium oxide, or using a treatment a fluorine based functional group, such as Perfluorobutanesulfonic acid (such as Scotchgard® from 3M) or a treatment with a perfluoroalkyl group (such as AG-E500D from Mitsubishi®).
  • a fluorine based functional group such as Perfluorobutanesulfonic acid (such as Scotchgard® from 3M) or a treatment with a perfluoroalkyl group (such as AG-E500D from Mitsubishi®).
  • a wax coating would also be suitable, howe ver was may be susceptible to wetting by epoxy or some liquid res s.
  • FIG. 17A-D illustrate coated abrasive articles made with a hydro-lipophobic coating applied to an attachment side of a backing prior to a make coat being applied on an abrasive side of the backing.
  • FIG. 17A illustrates a mesh backing 2100 coated with a make resin 2110.
  • FIG. 17B illustrates a mesh backing 2100 with precision shaped abrasive particles 2120 adhered to a make coat on the mesh backing.
  • FIG. 17C illustrates a mesh backing 2100 with crushed abrasive grains 2130 coated on a make resin.
  • FIG. 17D illustrates a view of the back 2160 of the abrasive article of FIG. 17C. As illustrated, there is substantially no make coat bleeding through onto the attachment side of the backing. Loops 2140 and backside 2150 of mesh are substantially free of make resin.
  • FIGS . 17E and 17F illustrate a comparative backing coated with a make resin without an applied hydrophobic coating.
  • FIG. 17E illustrates a coated side 2170
  • FIG. 17F illustrates a loop side 2180.
  • make resin has permeated through from the coated side 2170 to loop side 2180.
  • FIG. 18 illustrates a method of making a coated abrasive article.
  • Method 2200 may allow for more efficient and cheaper manufacturing of coated abrasive articles on open substrates, such as an open mesh backing.
  • a loop side coating is applied to a backing substrate .
  • the loop side coating is a hydrophobic coating 2202, for example, such as tetramethyl silane, titanium oxide, or treatment with a fluorinated compound.
  • Another treatment 2206 may also be applied.
  • a plasma treatment may be used to make a loop-side of a backing hydrophobic.
  • the hydrophobic coating applied in block 2210 may be a temporary coating that dissipates over time or is otherwise removed during use, in one embodiment.
  • the hydrophobic coating is a layer applied to the backing that is maintained through manufacturing and abrading of a workpiece using the coated abrasive article.
  • a make coat is applied to the abrasive side of the backing, opposite the hydrophobic coated side of the backing.
  • the make coat may be a resin coating 2212 or a hot melt adhesive coating 2214, as described herein. Applying a make coat may also comprise applying a separate laminate coating layer 2216, as described herein.
  • the laminate layer may be a blown melty film 2218, or another coating layer 2222.
  • the make coat may be applied using a roll coating method, as illustrated in block 2224, or using a knife coating method, as illustrated in block 2226. Other suitable methods may also be used, as illustrated in block 2228.
  • the hydrophobic coating on the loop side of the backing prevents the make coat, when applied to the backing, from bleeding through the substrate and onto the loop side.
  • the loop side of the backing is substantially free of make coat.
  • abrasive particles are applied to the make layer.
  • the abrasive particles may be shaped abrasive particles 2231, crushed abrasive particles, 2232, agglomerates 2234, or other particles 2236 as described herein.
  • the abrasive particles may embed within the make resin and thus adhere to the backing.
  • Additional coating layers may also be applied to the adhered particles, including a size coat, a supersize coat, grinding aid or additional functional layers.
  • the term “substantially” as used herein refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more.
  • substantially no refers to a minority of, or mostly no, as in less than about 10%, 5%, 2%, 1%, 0.5%, 0.01%, 0.001%, or less than about 0.0001% or less.
  • An abrasive article includes a fabric substrate comprising strands forming first void spaces between the strands, the fabric substrate comprising an abrasive side and an attachment side.
  • the abrasive article also includes a coating on the attachment side, and a make layer joined to the fabric substrate on the abrasive side, and abrasive particles joined to the make layer.
  • the abrasive article also includes a plurality of second void spaces extending through the make layer coinciding with first void spaces in the fabric substrate.
  • the coating on the fabric substrate reduces the surface energy and features both hydrophobic and lipophobic properties.
  • the attachment side of the fabric substrate is substantially free of make layer.
  • the abrasive article may be implemented such that the coated attachment side includes one part of a two-part hook and loop attachment system. [00122] The abrasive article may be implemented such that the fabric substrate comprises a woven or knitted material.
  • the abrasive article may be implemented such that the abrasive particles comprise shaped abrasive particles.
  • the abrasive article may be implemented such that the abrasive particles comprise agglomerate abrasive particles, and wherein the agglomerate abrasive particles comprise shaped abrasive particles.
  • the abrasive article may be implemented such that the agglomerate abrasive particles are shaped agglomerate abrasive particles, and wherein the shape comprises an nonagon, an octagon, a heptagon, a hexagon, a triangle, a parallelogram, a rhombus, a rectangle, a square, a pentagon, a circle, an oval, a heart, a cross, an arrow, a star, or a crescent.
  • the abrasive article may be implemented such that the agglomerate abrasive particles are arranged in a pattern on the fabric substrate.
  • the abrasive article may be implemented such that the agglomerate abrasive particles are arranged randomly on the fabric substrate.
  • the abrasive article may be implemented such that air flows through the article at a rate of at least 0.5 L/s, such that, when in use, dust can be removed from an abraded surface through the abrasive article.
  • the abrasive article may be implemented such that the make coat comprises a resin or a hot melt.
  • the abrasive article may be implemented such that the coating comprises applying a plasma treatment in a hydrophobic and lipophobic atmosphere.
  • the abrasive article may be implemented such that the plasma treatment comprises a fluorochemical or a silane.
  • the abrasive article may be implemented such that the coating comprises a hydrophobic and lipophobic chemical.
  • the abrasive article may be implemented such that the chemical is a fluorinated compound, a silane or a silicone.
  • the abrasive article may be implemented such that the coating comprises nanoparticles.
  • the abrasive article may be implemented such that the nanoparticles are silica nanoparticles or carbon nanotubes.
  • the abrasive article may be implemented such that it includes a size coat.
  • the abrasive article may be implemented such that it includes a supersize coat.
  • the abrasive article may be implemented such that the supersize coat is a stearate coating.
  • a method of making an abrasive article includes coating an attachment side of a fabric substrate with a hydrophobic coating material, joining a make layer composition to the fabric substrate on an abrasive side of the fabric substrate and joining abrasive particles to the make layer composition.
  • the fabric substrate comprises strands forming first void spaces between the strands.
  • the method may be implemented such that it also includes curing the curable resin composition to provide a cured resin composition.
  • the method may be implemented such that it also includes the curing creates a plurality of second void spaces coinciding with first void spaces in the fabric substrate.
  • the method may be implemented such that the abrasive particles comprise agglomerate abrasive particles, and wherein the agglomerate abrasive particles comprise shaped abrasive particles.
  • the method may be implemented such that the agglomerate abrasive particles are shaped agglomerate abrasive particles, and wherein the shape comprises an nonagon, an octagon, a heptagon, a hexagon, a triangle, a parallelogram, a rhombus, a rectangle, a square, a pentagon, a circle, an oval, a heart, a cross, an arrow, a star, or a crescent.
  • the method may be implemented such that joining the abrasive agglomerates to the curable resin composition comprises depositing the abrasive agglomerates in a pattern.
  • the method may be implemented such that joining the abrasive agglomerates to the curable resin composition comprises depositing the abrasive agglomerates randomly.
  • the method may be implemented such that the make coat comprises a resin or a hot melt.
  • the method may be implemented such that the coating comprises a plasma treatment.
  • the method may be implemented such that the coating comprises a fluorinated compound.
  • the method may be implemented such that it also includes joining a size layer composition to the abrasive particle layer.
  • the method may be implemented such that it also includes joining a supersize layer composition to the size layer.
  • An abrasive article includes a fabric substrate comprising a plurality of strands forming first void spaces between the strands, an adhesive layer comprising adhesive bonded to the plurality of strands and abrasive particles embedded within the adhesive layer.
  • the abrasive article may be implemented such that the adhesive layer comprises a heat activated adhesive.
  • the abrasive article may be implemented such that the abrasive particles are crushed abrasive particles, platey abrasive particles, formed abrasive particles, shaped abrasive particles, or partially shaped abrasive particles.
  • the abrasive article may be implemented such that the abrasive particles comprise agglomerate abrasive particles, and wherein the agglomerate abrasive particles comprise shaped abrasive particles.
  • the abrasive article may be implemented such that the agglomerate abrasive particles are shaped agglomerate abrasive particles, and wherein the shape comprises an nonagon, an octagon, a heptagon, a hexagon, a triangle, a parallelogram, a rhombus, a rectangle, a square, a pentagon, a circle, an oval, a heart, a cross, an arrow, a star, or a crescent.
  • the abrasive article may be implemented such that the abrasive agglomerates are embedded in the adhesive layer in a pattern.
  • the abrasive article may be implemented such that the abrasive agglomerates are embedded in the adhesive layer randomly.
  • the abrasive article may be implemented such that the adhesive layer is bonded to the plurality of strands on an adhesive side of the fabric substrate, and wherein, on an attachment side, the fabric substrate is coated with a hydrophobic coating.
  • the abrasive article may be implemented such that the hydrophobic coating comprises a plasma treatment.
  • the abrasive article may be implemented such that the hydrophobic coating comprises fluorinated compound.
  • a method of making an abrasive article includes applying a hydrophobic coating to an attachment side of a fabric substrate and applying an adhesive layer to an abrasive side of the fabric substrate.
  • the fabric substrate comprises strands forming first void spaces between the strands.
  • the adhesive layer is applied such that adhesive adheres substantially only to the strands and does not substantially extend into the void spaces.
  • the method also includes applying a plurality of abrasive particles to the adhesive layer such that the abrasive particles are partially embedded within the adhesive layer.
  • the method may be implemented such that the adhesive layer comprises a heat activated adhesive.
  • the method may be implemented such that applying an adhesive layer comprises laminating the fabric substrate with an adhesive layer.
  • the method may be implemented such that it also includes heating the adhesive layer.
  • the method may be implemented such that applying the plurality of abrasive particles comprises drop-coating the abrasive particles.
  • the method may be implemented such that the abrasive particles are heated.
  • the method may be implemented such that the adhesive layer is heated.
  • the method may be implemented such that it also includes applying a size coat.
  • the method may be implemented such that it also includes applying a supersize coat.
  • the method may be implemented such that the abrasive particles comprise agglomerate abrasive particles.
  • the agglomerate abrasive particles comprise shaped abrasive particles.
  • the method may be implemented such that the agglomerate abrasive particles are shaped agglomerate abrasive particles, and wherein the shape comprises an nonagon, an octagon, a heptagon, a hexagon, a triangle, a parallelogram, a rhombus, a rectangle, a square, a pentagon, a circle, an oval, a heart, a cross, an arrow, a star, or a crescent.
  • the method may be implemented such that applying the abrasive agglomerates to the adhesive layer comprises depositing the abrasive agglomerates in a pattern.
  • the method may be implemented such that applying the abrasive agglomerates to the adhesive layer comprises depositing the abrasive agglomerates randomly.
  • a sheet of MESH of about 22.9 cm x 22.9 cm were mounted on the powered electrode of Reactor One with the loop side facing up to the chamber atmosphere.
  • the reactor chamber was pumped down to a base pressure of less than 1.3 Pa (lO mTorr).
  • TMS tetramethylsilane
  • O2 available in gas cylinders from Oxygen Service Company, Minneapolis, Minn.
  • the total chamber pressure was 23.9 Pa (180 mTorr).
  • a plasma was ignited with radio frequency (RF) power of 450 watts.
  • RF radio frequency
  • Plasma treatment was continued for two minutes. After extinguishing the plasma, the gas flows were stopped, the chamber pressure brought down to below 10 mTorr, after which the chamber was vented to atmosphere. Details related to plasma processing and operation can be found in U.S. Patent No. 6,878,419 (David et al .) Multiple sheets were treated by repeating this process.
  • the first abrasive example was prepared with abrasive particles only coated on the raised yams of the coat side of the plasma-treated MESH: MKR was roll coated on the coat side of a treated MESH as mentioned above with about 76 pm controlled gap, and followed by drop coat of 4 grams of SAP on the top of MKR. Then the abrasive sample was put in oven for resin cure.
  • the second abrasive example was prepared with pattern-coated abrasive slurry on the coat side of the plasma-treated MESH: a 0.15 mm thick hexagon-patterned stencil, which has staggered hexagons as open areas with 2 mm of side and adjacent distance, was put on the top of the coat side of a treated MESH as mentioned above. All the edges were taped tightly to the MESH to ensure there was no space between the stencil and mesh web. Then SLU was coated through the stencil using a rubber squeegee. The stencil was removed after coating, and the abrasive sample was put in oven for resin cure.
  • a composition comprising 0.2 g AG-E500D (ASAHI GUARD E-SERIES AG-E500D, 30%, from AGC Chemicals Americas Inc. Exton, PA), l.Og sodium carboxymethyl cellulose (CMC, average Mw 90K, Sigma-Aldrich Company), 20.0 g hexanes (98.5% from Sigma-Aldrich Company), and 78.
  • Og water was blended with a high speed shearer (IKA EUROSTAR 200 Overhead Stirrer, IKA Works, Inc. Wilmington, NC) at a speed of 1500 rpm for 20 min to form a temporary stable foam solution.
  • the foam solution was applied onto the loop side of the MESH backing with a knife coater with the add-on of 11.8g on 250 square centimeters area.
  • the sample was dried at 80C for 5 minutes and then cured at 105C for 1 minute.
  • the treated MESH backing was rinsed with 60C water and then dried at 105 C for 1 minute.
  • MKR2 was applied to the non-loop side of the treated MESH backing with knife coating. Pressurized air was then applied from the loop side to open the pores on the MESH backing. PI 50 grade SAP was drop coated onto the make resin and then the sample was dried at 90C for 60 minutes.
  • MKR2 on treated MESH backing is illustrated in FIG. 17A.
  • FIG. 17B Making coated MESH abrasive articles comprising SiC

Abstract

La présente divulgation concerne un article abrasif qui comprend un substrat de tissu doté de brins qui forment des premiers espaces vides entre eux. Le substrat de tissu comprend un côté abrasif et un côté de fixation. L'article abrasif comprend également un revêtement sur le côté de fixation. L'article abrasif comprend également une couche de fabrication jointe au substrat de tissu sur le côté abrasif. L'article abrasif comprend également des particules abrasives liées à la couche de fabrication. L'article abrasif comprend également une pluralité de seconds espaces vides s'étendant à travers la couche de fabrication et coïncidant avec des premiers espaces vides dans le substrat de tissu. Le revêtement sur le substrat de tissu est à la fois hydrophobe et lipophobe. Le côté de fixation du substrat de tissu est sensiblement exempt de couche de fabrication.
EP21713142.4A 2020-03-18 2021-03-15 Article abrasif Pending EP4121249A1 (fr)

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