Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
  • B24D11/00—Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
  • B24D11/001—Manufacture of flexible abrasive materials
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
  • B24D11/00—Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
  • B24D11/02—Backings, e.g. foils, webs, mesh fabrics
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
  • B24D7/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting otherwise than only by their periphery, e.g. by the front face; Bushings or mountings therefor
  • B24D7/06—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting otherwise than only by their periphery, e.g. by the front face; Bushings or mountings therefor with inserted abrasive blocks, e.g. segmental
  • B24D7/063—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting otherwise than only by their periphery, e.g. by the front face; Bushings or mountings therefor with inserted abrasive blocks, e.g. segmental with segments embedded in a matrix which is rubbed away during the grinding process

Definitions

• the present disclosure broadly relates abrasive articles, and methods of making and using the same.
• Abrasive articles having an abrasive layer disposed on a porous and/or perforated backing are especially useful for abrading applications (e.g., sanding auto body filler) where dust removal during use is desired.
• Screen abrasives generally have an abrasive layer disposed on an open mesh substrate such as, for example, a wire screen, glass fiber woven mesh, unitary plastic mesh, or polymer fiber (e.g., polyimide fiber) woven mesh.
• the abrasive layer had abrasive particles dispersed in a binder material.
• Screen abrasive are typically used for applications where lots of dust may generated such as, for example, vehicle body repair and drywall sanding, because the porous nature of these products allows dust to pass through the screen abrasive and not load the abrasive layer thereby reducing abrading performance.
• Certain coated abrasive articles e.g., sandpaper, grinding discs, and abrasive belts
• a relatively dense planar backing e.g., vulcanized fiber or a woven or knit fabric, optionally treated with a saturant to increase durability
• These products are often more aggressive than corresponding screen abrasives (i.e., having the same shape, orientation, and type of abrasive particles); however, they can become loaded with swarf during use, thereby reducing abrading performance.
• Composite abrasive articles according to the present disclosure combine abrading performance of the abovementioned coated abrasive articles with the dust removal benefits of screen abrasives.
• the present disclosure provides a composite abrasive article comprising: an open mesh backing member having first and second major surfaces; and coated abrasive members secured to the first major surface of the open mesh backing member, wherein each coated abrasive member independently respectively comprises: an abrasive layer comprising abrasive particles secured to a coated abrasive backing by at least one binder material.
• the present disclosure provides a method of making a composite abrasive article comprising: providing an open mesh backing member having first and second major surfaces; and securing coated abrasive members to the first major surface, wherein each coated abrasive member independently respectively comprises: an abrasive layer comprising abrasive particles secured to a coated abrasive backing by at least one binder material.
• the present disclosure provides a method of using a composite abrasive article, the method comprising: frictionally contacting the abrasive layer of at least one of the coated abrasive members of a coated abrasive article according to the present disclosure with a surface of a workpiece; and moving at least one of the coated abrasive article or the workpiece relative to the other to abrade the surface of the workpiece.
• the term "mesh” refers to a substantially two-dimensional screen which may be a woven fabric or unitary plastic sheet having closely spaced geometrically shaped openings (e.g., triangular, square, rectangular, round, hexagonal, or a combination thereof).
• FIG. 1 is a schematic perspective view of an exemplary composite abrasive article 100 according to the present disclosure.
• FIG. 1A is a schematic enlarged side view of composite abrasive article 120 attached to open mesh backing member 110.
• FIG. 2 is a schematic plan view of an exemplary woven open mesh backing 200.
• FIG. 3 is a schematic plan view of an exemplary unitary plastic sheet 300.
• FIG. 4 is a schematic side view of an exemplary coated abrasive member 400.
• composite abrasive article 100 comprises an open mesh backing member 110 having first and second major surfaces (112, 114). Coated abrasive members 120 are secured to the first major surface 112. Optional attachment element 130 (e.g., the hooked portion or looped portion of a hook and loop fastener) is secured to second major surface 114. Coated abrasive members 120 are arranged according to a predetermined hexagonal pattern. Referring now to FIG. 1A, coated abrasive member 120 is secured to the first major surface 112 of the open mesh backing member 110 by adhesive layer 140 sandwiched therebetween.
• adhesive layer 140 sandwiched therebetween.
• unitary plastic open mesh backing 300 has openings 310. further comprising securing an attachment element to the second major surface of the open mesh backing member opposite the coated abrasive members.
• Useful backings members may include wire screen, glass fiber woven mesh, unitary plastic mesh, or polymer fiber (e.g., polyimide fiber) woven mesh, for example as long as it has openings of sufficient size and quantity to make it porous enough for dust to pass through.
• polymer fiber e.g., polyimide fiber
• the attachment element may comprise, for example, a looped portion of a hook and loop fastening system, or stem-web (interlocking mechanical mushroom shaped features) fastener system.
• the attachment element comprises nonwoven, woven or knitted loop material.
• it comprises hook material, e.g., as described in U.S. Pat. No. 5,058,247 (Thomas et ak).
• coated abrasive article 400 has a backing 420 and abrasive layer 430.
• Abrasive layer 430 includes abrasive particles 440 according to the present disclosure secured to a major surface 470 of backing 420 (substrate) by make coat 450 and size coat 460. Additional layers, for example, such as an optional supersize layer 480 that is superimposed on the size layer, or a backing antistatic treatment layer (not shown) may also be included, if desired.
• Coated abrasive members which may be prepared from corresponding coated abrasive articles well-known in the abrasives art and/or marketed commercially.
• the make and or size layer can be formed by coating a curable precursor onto a major surface of the backing and curing it.
• the curable precursor may comprise, for example, glue, phenolic resin, aminoplast resin, urea-formaldehyde resin, melamine-formaldehyde resin, urethane resin, free-radically polymerizable polyfunctional (methjacrylate (e.g., aminoplast resin having pendant a,b-unsaturated groups, acrylated urethane, acrylated epoxy, acrylated isocyanurate), epoxy resin (including bis- maleimide and fluorene-modified epoxy resins), isocyanurate resin, and mixtures thereof.
• methjacrylate e.g., aminoplast resin having pendant a,b-unsaturated groups, acrylated urethane, acrylated epoxy, acrylated isocyanurate
• epoxy resin including bis- maleimide and fluorene-modified epoxy resins
• isocyanurate resin and
• phenolic resin is used to form the make layer, it is likewise preferably used to form the size layer.
• the curable precursor may be applied by any known coating method for applying a make or size layer to a backing, including roll coating, extrusion die coating, curtain coating, knife coating, gravure coating, spray coating, or screen printing, for example.
• the basis weight of the make and size layers will also necessarily vary depending on the intended use(s), type(s) of abrasive particles, and nature of the coated abrasive member being prepared, but generally will be in the range of from 1 or 5 gsm to 300, 400, or even 500 gsm, or more.
• the make and/or size layers may further contain optional additives, for example, to modify performance and/or appearance.
• Exemplary additives include grinding aids, fillers, plasticizers, wetting agents, surfactants, pigments, coupling agents, fibers, lubricants, thixotropic materials, antistatic agents, suspending agents, and/or dyes.
• the optional supersize layer typically includes grinding aids and/or anti-loading materials.
• the optional supersize layer may serve to prevent or reduce the accumulation of swarf (the material abraded from a workpiece) between abrasive particles, which can dramatically reduce the cutting ability of the coated abrasive disc.
• Useful supersize layers typically include a grinding aid (e.g., potassium tetrafluoroborate), metal salts of fatty acids (e.g., zinc stearate or calcium stearate), salts of phosphate esters (e.g., potassium behenyl phosphate), phosphate esters, urea-formaldehyde resins, mineral oils, crosslinked silanes, crosslinked silicones, and/or fluorochemicals.
• a grinding aid e.g., potassium tetrafluoroborate
• metal salts of fatty acids e.g., zinc stearate or calcium stearate
• salts of phosphate esters e.g., potassium behenyl phosphate
• phosphate esters e.g., potassium behenyl phosphate
• phosphate esters e.g., urea-formaldehyde resins
• mineral oils e.g., crosslinked silanes, crosslinked silicones
• the amount of grinding aid incorporated into coated abrasive products is about 50 to about 400 gsm, more typically about 80 to about 300 gsm.
• the supersize may contain a binder such as for example, those used to prepare the size or make layer, but it need not have any binder.
• Suitable abrasive particles may include any known abrasive particles or materials commonly used in abrasive articles.
• useful 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, tungsten carbide, titanium carbide, diamond, cubic boron nitride, garnet, fused alumina zirconia, sol gel abrasive particles, silica, iron oxide, chromia, ceria, zirconia, titania, silicates, metal carbonates (such as calcium carbonate (e.g., chalk, calcite, marl, travertine, marble and limestone), calcium magnesium carbonate, sodium carbonate, magnesium carbonate), silica (e.g., quartz, glass beads, glass bubbles and glass fibers) silicates (e.g., talc, clays, (montmorillonite) feldspar, mica, calcium
• the abrasive particles may also be agglomerates or composites that include additional components, such as, for example, a binder. Criteria used in selecting abrasive particles used for a particular abrading application typically include abrading life, rate of cut, substrate surface finish, grinding efficiency, and product cost. Useful abrasive particles also include shaped abrasive particles (e.g., precisely-shaped abrasive particles). Details concerning such abrasive particles and methods for their preparation can be found, for example, inU.S. Pat. No.
• coated abrasive discs comprising an abrasive layer secured to a backing, wherein the abrasive layer comprises abrasive particles and make, size, and optional supersize layers are well known, and may be found, for example, in U. S. Pat. Nos.
• the coated abrasive member(s) may be secured to the porous backing member by any suitable method including, for example, stitchbonding, interlocking fasteners (e.g., mushroom-type, hooked), welding (e.g., spin welding), and/or adhesive bonding with a layer of adhesive.
• Useful adhesives may include glue, hot melt adhesives (e.g., styrene-butadiene polymers), latex adhesives, pressure-sensitive adhesives (e.g. acrylic pressure-sensitive adhesives), and/or thermosetting adhesives (e.g., epoxy, acrylic, or polyurethane adhesives).
• Composite abrasive articles according to the present disclosure can be readily made by adhering the coated abrasive members to the open mesh backing member randomly or according to a predetermined pattern, for example.
• the coated abrasive members may have any shape and or size suitable for manufacture of the composite abrasive articles. Exemplary shapes may include triangles, squares, hexagons, circles, ellipses, rectangles, and/or random shapes.
• coated abrasive members comprise material from scrap in commercial production of a coated abrasive product.
• the present disclosure provides a composite abrasive article comprising: an open mesh backing member having first and second major surfaces; and coated abrasive members secured to the first major surface of the open mesh backing member, wherein independently each coated abrasive member respectively comprises: an abrasive layer comprising abrasive particles secured to a coated abrasive backing by at least one binder material.
• the present disclosure provides a composite abrasive article according to the first embodiment, wherein each of the coated abrasive members is independently secured to the first major surface by at least one respective adhesive layer sandwiched therebetween.
• the present disclosure provides a composite abrasive article according to the first or second embodiment, further comprising an attachment element secured to the second major surface of the open mesh backing member and disposed opposite the coated abrasive members.
• the present disclosure provides a composite abrasive article according to any of the first to third embodiments, wherein the coated abrasive members comprise a make layer, a size layer, and optionally a supersize layer.
• the present disclosure provides a composite abrasive article according to any of the first to fourth embodiments, wherein the coated abrasive members are arranged according to a predetermined pattern.
• the present disclosure provides a composite abrasive article according to any of the first to fifth embodiments, wherein the coated abrasive members are compositionally the same.
• the present disclosure provides a composite abrasive article according to any of the first to sixth embodiments, wherein the coated abrasive members have the same shape and size.
• the present disclosure provides a composite abrasive article according to any of the first to seventh embodiments, wherein said at least one respective adhesive layer comprises hot melt adhesive.
• the present disclosure provides a composite abrasive article according to any of the first to eighth embodiments, wherein said at least one respective adhesive layer comprises thermosetting adhesive.
• the present disclosure provides a composite abrasive article according to any of the first to ninth embodiments, the open mesh backing member comprises a woven mesh.
• the present disclosure provides a composite abrasive article according to any of the first to ninth embodiments, wherein the open mesh backing member comprises a unitary plastic sheet or belt.
• the present disclosure provides a method of making a composite abrasive article, the method comprising: providing an open mesh backing member having first and second major surfaces; and securing coated abrasive members to the first major surface, wherein each coated abrasive member independently respectively comprises: an abrasive layer comprising abrasive particles secured to a coated abrasive backing by at least one binder material.
• the present disclosure provides a method according to the twelfth embodiment, wherein said securing coated abrasive members to the first major surface is accomplished with adhesive.
• the present disclosure provides a method according to the twelfth or thirteenth embodiment, wherein the open mesh backing member further comprises an attachment element opposite the coated abrasive members.
• the present disclosure provides a method of using a composite abrasive article, the method comprising: frictionally contacting the abrasive layer of at least one of the coated abrasive members of the coated abrasive article of any of the first to eleventh embodiments with a surface of a workpiece; and moving at least one of the coated abrasive article or the workpiece relative to the other to abrade the surface of the workpiece.
• Example 1 The procedure of Example 1 was repeated, except that the ADH/ABR composite was cut into triangles of dimensions 25 mm x 25 mm x 35 mm.
• Loop-backed abrasive discs (6-inch (15.24 cm)), obtained as 3M Hookit Purple Clean Sanding Abrasive Disc 334U from 3M Company.
• the discs had a paper-based backing.
• Abrasive performance testing was performed on 18 inches long by 24 inches wide (45.7 cm by 61 cm) black painted cold roll steel test panels having NEXA AOEM type clearcoat, obtained from ACT Laboratories, Inc., Hillsdale, Michigan.
• the abrasive discs were attached to a 6-inch (15.2 cm) backup pad commercially available as 3M #05551 Purple Cleansand Painters pad from 3M Company.
• the tool was disposed over an X-Y table, with the test panel secured to the X-Y table.
• the abrasive discs were attached to the backup pad. Sanding was performed using a dual action axis of a servo controlled motor operating at 6000 rpm. The dual action axis had a 3/16 inch (4.76 mm) stroke length.
• the servo-driven sanding mechanism was disposed over an X-Y table and the abrasive article held at an angle of 2.5 degrees against the panel at a load of 13 lbs (5.91 kg). The tool was then set to traverse in the X direction along the width of the panel at the rate of 2.53 inches/second (6.4 cm/second) and in Y direction at the rate of 20 inches/second (50.8 cm/second) along the length of the panel.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Polishing Bodies And Polishing Tools (AREA)

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• 2021
  • 2021-05-17 US US17/998,939 patent/US20230226664A1/en active Pending
  • 2021-05-17 WO PCT/IB2021/054217 patent/WO2021234540A1/en unknown
  • 2021-05-17 EP EP21727568.4A patent/EP4153380A1/de active Pending

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