US20190255677A1 - Sandpaper with non-slip coating layer - Google Patents

Sandpaper with non-slip coating layer Download PDF

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Publication number
US20190255677A1
US20190255677A1 US16/340,554 US201716340554A US2019255677A1 US 20190255677 A1 US20190255677 A1 US 20190255677A1 US 201716340554 A US201716340554 A US 201716340554A US 2019255677 A1 US2019255677 A1 US 2019255677A1
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United States
Prior art keywords
sandpaper
slip
coating layer
slip coating
layer
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US16/340,554
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English (en)
Inventor
Michael C. Martin
Stewart W. CAMPBELL
Ignatius A. Kadoma
Brett A. Buchholz
Elizabeth A. Benson-Sargent
John G. Petersen
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3M Innovative Properties Co
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3M Innovative Properties Co
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Priority to US16/340,554 priority Critical patent/US20190255677A1/en
Publication of US20190255677A1 publication Critical patent/US20190255677A1/en
Assigned to 3M INNOVATIVE PROPERTIES COMPANY reassignment 3M INNOVATIVE PROPERTIES COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PETERSEN, JOHN G., BENSON-SARGENT, Elizabeth A., KADOMA, IGNATIUS A., CAMPBELL, Stewart W., BUCHHOLZ, BRETT A., MARTIN, MICHAEL C.
Abandoned legal-status Critical Current

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    • 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
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/34—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties
    • B24D3/346—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties utilised during polishing, or grinding operation
    • 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
    • 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
    • B24D11/08—Equipment for after-treatment of the coated backings, e.g. for flexing the coating
    • 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
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/34—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D9/00—Wheels or drums supporting in exchangeable arrangement a layer of flexible abrasive material, e.g. sandpaper

Definitions

  • the present disclosure generally relates to abrasive articles for abrading a work surface such as, for example, flexible sheet-like abrasive articles, as well as methods of making and using such abrasive articles.
  • Sheet-like abrasive articles are commonly used in a variety of sanding operations including, for example, hand sanding of wooden surfaces.
  • hand sanding the user holds the abrasive article directly in his or her hand and moves the abrasive article across the work surface.
  • Sanding by hand can, of course, be an arduous task.
  • Sheet-like abrasive articles include, for example, conventional sandpaper.
  • Conventional sandpaper is typically produced by affixing abrasive material to a relatively thin, generally non-extensible, non-resilient, non-porous backing (e.g., paper).
  • the thin, flat, slippery nature of conventional sandpaper backing materials makes conventional sandpaper difficult to grasp, hold, and maneuver. Because of the slippery nature of conventional sandpaper, to hold a sheet of sandpaper securely, a user will grasp the sheet of sandpaper between his or her thumb and one or more of his or her remaining fingers. Holding the sandpaper in this manner is uncomfortable, can lead to muscle cramps and fatigue, and is difficult to maintain for an extended period of time.
  • the thumb is typically in contact with the abrasive surface of the sandpaper, which can irritate or damage the skin. Also, because the thumb is positioned between the sandpaper and the work surface, grasping the sandpaper in this manner interferes with the sanding operation. That is, due to the position of the thumb, a portion of the sandpaper abrasive surface is lifted away from the work surface during sanding. Because the lifted portion is not in contact with the work surface, the full sanding surface of the sandpaper is not utilized, and the effectiveness of the sandpaper is, therefore, diminished.
  • a user often applies pressure to the sandpaper using his or her fingertips. Because of the thin nature of the backing materials used in conventional sandpaper, the finger pressure is concentrated in the regions where the finger pressure is applied. This, in turn, causes the sandpaper to wear and/or load unevenly, and can produce an uneven sanding pattern on the work surface.
  • Some sandpaper can be used in either wet or dry environments. In wet environments, common applications include filler sanding, putty sanding, primer sanding and paint finishing.
  • a particular problem encountered with certain sandpaper in wet environments is the tendency for sheet-like article to curl. Curling of the abrasive article can be a significant nuisance to the user. A similar effect can also occur when abrasive articles are stored in humid environments. To mitigate curling, abrasive sheets are sometimes preflexed in the manufacturing process, but this is generally ineffective in preventing curling during use.
  • sandpaper is typically sold in standard size sheets, such as 9 ⁇ 11 inch sheets.
  • users often fold the sandpaper, thereby producing smaller sheets that are easier to handle.
  • Folding the sandpaper produces a jagged edge, and also weakens the sandpaper along the fold line. During the rigors of sanding, the weakened fold line may tear, thereby resulting in premature failure of the sandpaper.
  • 3M Company developed sandpaper that has a non-slip surface. Such sandpaper is described in, for example, U.S. Pat. No. 8,662,962.
  • the commercial product, 3M No-Slip GripTM Advanced Sandpaper provides at least some of the following advantages: improved handling, ease of use, comfortable use, relatively easy and inexpensive to manufacture, improved cut, improved durability, and produces finer scratches than a comparable sheet of sandpaper.
  • the inventors of the present disclosure learned that some users place sheets of sandpaper (or portions thereof) on power sanding tools. In some instances of high-speed use on power tools, the non-slip coating on the sandpaper can soften or melt, sticking to the power tool. The inventors of the present disclosure sought to formulate an improved no-slip grip coating that provides added heat resistance without significantly compromising the advantages of the existing non-slip sandpaper.
  • the present disclosure provides a sheet of sandpaper comprising (1) a backing layer having opposed first and second major surfaces, (2) an adhesive make coat directly on the first major surface, (3) abrasive particles at least partially embedded in the make coat, thereby defining an abrasive surface, and (4) a non-slip layer on the second major surface, the non-slip layer comprising (a) a dimer acid polyamide, (b) an elastomer, and (c) a tackifying agent.
  • this configuration provides a coated abrasive that displays superior curl-resistance and improved overall cut and finish performance as compared with prior art abrasive articles.
  • FIG. 1 is a cross sectional view of a sheet of sandpaper according to the disclosure
  • FIG. 2 is a perspective view of a second embodiment of the disclosure.
  • FIG. 3 is a photograph of various Examples during a Wet Curl test.
  • FIG. 1 shows a cross-section of a sheet-like abrasive article 10 , such as a sheet of sandpaper, comprising a flexible backing layer 12 having opposed first 12 a and second 12 b major surfaces, a flexible non-slip coating layer 14 on the backing layer first major surface 12 a, an adhesive make coat layer 16 on the backing layer second major surface 12 b, and a plurality of abrasive particles 18 at least partially embedded in the make coat layer 16 .
  • the abrasive article 10 may be provided in, for example, a stack of individual sheets, or in roll form, wherein the abrasive article 10 may have an indefinite length.
  • the expression “sheet-like” refers generally to the broad, thin, flexible nature of the abrasive article 10 .
  • coating refers generally to at least a single layer of generally flowable material, such as a liquid or a solid powder that can be applied directly to a surface. A coating, therefore, does not include a separate sheet of material laminated to a surface.
  • layer refers generally to the non-slip material forming a discrete stratum on top of the backing layer 12 (i.e., the non-slip material does not soak through the entire thickness of the backing layer 12 ).
  • the sheet-like abrasive article 10 may be used for hand sanding a work surface, such as a wooden surface or work piece. That is, the abrasive article 10 may be used to remove material from a surface by contacting the abrasive article 10 directly with one's hand (i.e., without the aid of a tool, such as a sanding block) via the non-slip coating layer 14 , and subsequently moving the abrasive article 10 against the work surface. It will be recognized that the present disclosure may also be used with manually-operated sanding tools and sanding blocks, or with power tools.
  • the backing layer 12 , the non-slip coating layer 14 , the adhesive make coat layer 16 , and the abrasive particles 18 are each described in detail below.
  • Suitable materials for the backing layer 12 include any of the materials commonly used to make sandpaper including, for example, paper, cloths (cotton, polyester, rayon) polymeric films such as thermoplastic films, foams, and laminates thereof.
  • the backing layer 12 will have sufficient strength for handling during processing, sufficient strength to be used for the intended end use application, and the ability to have the non-slip coating 14 and make coat 16 applied to at least one of its major surfaces.
  • the backing layer 12 is formed of paper.
  • paper is a desirable material for the backing layer 12 because it is readily available and is typically low in cost.
  • Paper backings are available in various weights, which are usually designated using letters ranging from “A” to “F”. The letter “A” is used to designate the lightest weight papers, and the letter “F” is used to designate the heaviest weight papers. As explained more fully below, the present disclosure allows any weight paper to be used without experiencing the drawbacks associated with conventional sandpaper backings noted above.
  • the backing layer 12 is continuous. That is, the backing layer 12 does not contain holes, openings, slits, voids, or channels extending there through in the Z-direction (i.e., the thickness or height dimension) that are larger than the randomly formed spaces between the material itself when it is made.
  • the backing may also contain openings (i.e., be perforated), or contain slits.
  • the backing layer 12 is generally non-extensible.
  • the term “non-extensible” refers to a material having an elongation at break of no greater than about 25%. In some embodiments, the material has an elongation at break of no greater than about 10%. In some embodiments, the material has an elongation at break of no greater than about 5%.
  • the backing layer 12 may be relatively thin, and typically has a thickness of no greater than about 1.5 mm, no greater than about 1 mm, or no greater than about 0.75 mm. In such embodiments, the backing layer 12 is generally not resilient.
  • the backing layer 12 may also be porous or non-porous.
  • the backing layer may be somewhat thicker. For example, in embodiments having a foam backing layer, the backing layer may have a thickness of at least about 2 mm, at least about 5 mm, or at least about 10 mm.
  • the backing layer 12 may also be formed of a cloth material or film, such as a polymeric film.
  • Cloth materials are desirable because they are generally tear resistant and are generally more durable than paper and film materials.
  • cloth backings tolerate repeated bending and flexing during use.
  • Cloth backings are generally formed of woven cotton or synthetic yarns that are treated to make them suitable for use as a coated abrasive backing.
  • cloth backings are available in various weights, which are usually designated using a letter ranging from “J” to “M” with the letter “J” designating the lightest weight cloth, and the letter “M” designating the heaviest weight cloths.
  • Suitable film materials for the backing layer 12 include polymeric films, including primed films, such as polyolefin film (e.g., polypropylene including biaxially oriented polypropylene, polyester film, polyamide film, cellulose ester film).
  • the backing layer 12 includes a polyurethane, such as those described in US Publication No. 2017/0043450 (Graham et al.), including at least one thermoplastic polyurethane (TPU).
  • the backing may comprise a single thermoplastic polyurethane or a combination of thermoplastic polyurethanes.
  • One suitable class of polyurethanes is aromatic polyether-based polyurethanes, particularly thermoplastic polyether-based polyurethanes.
  • the thermoplastic polyether-bases polyurethanes are derived from 4,4′-methylenedicyclohexyl diisocyanate (MDI), a polyether polyol, and butanediol.
  • MDI 4,4′-methylenedicyclohexyl diis
  • the sandpaper 10 includes a non-slip coating layer 14 , which defines a non-slip, or slip resistant, outer surface 14 a of the sandpaper 10 .
  • “Non-slip” or “slip resistant” coatings, layers, or materials refer to coatings, layers, or materials that tend to increase the coefficient of friction of the backing layer surface to which the non-slip material is applied.
  • the coating is a “non-slip” coating.
  • the coating tends to increase the coefficient of friction of the backing surface to which it is applied, then the coating qualifies as a “non-slip” coating.
  • the non-slip coating layer 14 has an average peak static coefficient of friction of at about 1 gram, at least about 1.25 grams, or at least about 1.5 grams when measured according to ASTM D 1894-08 (Standard Test Method for Static and Kinetic Coefficients of Friction of Plastic Film and Sheeting) at 23° C. using an IMASS slip/peel tester (SP2000, commercially available from Instrumentors Inc., Strongsville, Ohio), and/or an average kinetic coefficient of friction of at least about 0.75 grams, at least about 1 gram, or at least about 1.25 grams
  • the non-slip coating layer 14 is provided on the first major surface 12 a of the backing layer 12 opposite the make coat 16 and abrasive particles 18 .
  • the non-slip coating layer 14 outer surface 14 a may have no tack, or have a low level of tackiness.
  • Tack or tackiness refers to the stickiness or adhesive properties of a material.
  • Non-tacky refers to a material that does not possess any degree of stickiness or adhesive properties, whereas tacky materials possess some degree of stickiness or adhesive properties.
  • Non-tacky materials may possess a high coefficient of friction, therefore also making non-tacky materials useful as non-slip coatings.
  • the non-slip coating is tacky, it is desirable that it have a low level of tackiness.
  • low level of tackiness it is meant that the non-slip coating has an average tack level, as measured by ASTM D2979-01 (Standard Test Method for Tack of Pressure-Sensitive Adhesives Using an Inverted Probe Machine) using a ten (10) second dwell time, and a probe removal speed of one (1) cm/s, of no greater than about 200 grams, no greater than about 250 grams, no greater than about 300 grams, and no greater than about 350 grams. It is desirable that the material used to form the non-slip coating layer 14 bond directly to the backing layer 12 . If the non-slip material does not form an effective bond with the backing layer, the backing layer 12 may be primed to allow the non-slip material to form a more effective bond with the backing layer 12 .
  • the non-slip coating 14 is slightly tacky, and has an adhesion to itself that is less than the cohesive strength of the non-slip coating itself, and further has an adhesion to itself that is less than the “two-bond” adhesive strength.
  • the “two-bond” adhesive strength is the adhesive strength between the non-slip coating 14 and the backing layer 12 to which the non-slip coating layer is applied.
  • the non-slip coating provides a surface that may be repeatably bonded to itself.
  • the non-slip coating 14 may be repositionable.
  • repositionable refers to a non-slip coating that allows repeated application, removal, and reapplication to and from itself or a surface without damage to the non-slip coating or the surface.
  • the adhesion of the non-slip coating layer 14 to itself not build significantly over time.
  • the abrasive article 10 may later be readily unfolded by separating the non-slip coating layers 14 without damaging the non-slip coating 14 or the backing layer 12 .
  • Suitable materials for the non-slip coating layer 14 include, for example, elastomers.
  • Suitable elastomers include: natural and synthetic rubbers such as synthetic polyisoprene, butyl rubbers, polybutadiene, styrene-butadiene rubber (SBR), block copolymers such as Kraton rubber, polystyrene-polyisoprene-polystyrene (SIS) rubber, styrene-butadiene-styrene (SBS) rubber, nitrile rubber (Buna-N rubbers), hydrogenated nitrile rubbers, acrylonitrile butadiene rubber (NBR), chloroprene rubber, polychloroprene, neoprene, EPM rubber (ethylene propylene rubber), EPDM rubber (ethylene propylene diene rubber), acrylic rubber, polyacrylic rubber, silicone rubber, ethylene-vinyl acetate (EVA), polyvinyl acetate (
  • Such rubber materials may further include a tackifying agent.
  • exemplary tackifiers include, for example, C5 and C9 tackifiers.
  • Exemplary commercially available tackifiers include Wingtack type tackifier resins, available from TOTAL Cray Valley, Exton, Pa.
  • the non-slip coatings of the present disclosure further include a dimer acid polyamide.
  • the dimer acid polyamide assists in providing heat resistance to the non-slip coating or layer.
  • Dimer acids can be obtained by the polymerization of C18-acids such as oleic and linoleic acids, and are often environmentally friendly chemical reagents with characteristics of being biodegradable.
  • Polyamides can be prepared by melt-polycondensation reactions using dimer acids and different diamines as raw materials. The dimer acid-based polyamides synthesized possess advantages of being soluble in many solvents, biodegradable, flexible and demonstrating good hot melt adhesion.
  • dimer acid-based polyamides can be found, for example, in U.S. Pat. No. 3,377,303 (Peerman et al.) U.S. Pat. No. 3,483,237 (Peerman et al.); U.S. Pat. No. 5,085,099 (Jaeger); U.S. Pat. No. 5,138,027 (Van Beek); and U.S. Pat. No. 5,455,326 (Parker)
  • the non-slip coating or layer includes between about 20% and about 55% by weight of dimer acid polyamide. In some embodiments, the non-slip coating or layer includes between about 25% and about 50% by weight of dimer acid polyamide. In some embodiments, the non-slip coating or layer includes between about 30% and about 45% by weight of dimer acid polyamide. In some embodiments, the non-slip coating or layer includes greater than about 20% by weight of dimer acid polyamide or greater than about 25% by weight of dimer acid polyamide, or greater than about 30% by weight of dimer acid polyamide, or greater than about 35% by weight of dimer acid polyamide, or greater than about 40% by weight of dimer acid polyamide.
  • the non-slip coating or layer includes less than about 55% by weight of dimer acid polyamide or less than about 50% by weight of dimer acid polyamide or less than about 45% by weight of dimer acid polyamide or less than about 40% by weight of dimer acid polyamide or less than about 35% by weight of dimer acid polyamide.
  • the dimer acid polyamide is present in a ratio of between about 70:16 and about 31:55 (dimer acid polyamide: SIS block copolymer).
  • dimer acid polyamides include UNIREZ resins, available from Kraton Corporation, Houston, Tex.
  • the non-slip coating on the sandpaper may soften or melt and stick to the power tools, and potentially ruining the power tool. It is desirable that the coating have a low hot melt adhesion to address this issue without significantly compromising the advantages of a non-slip sandpaper.
  • a test method was developed to measure the relative hot melt adhesion of compounded formulations to a steel surface. Please see the Relative Hot-Melt Adhesion Test Method description below. It is desirable that the relative hot-melt adhesion (according to this test method) generate an axial force at 80° C. below ⁇ 18 Newtons, preferably in the range ⁇ 15 Newtons to ⁇ 5 Newtons.
  • the tackiness of such elastomeric non-slip coating layers may be adjusted by adding fillers, such as calcium carbonate, to the material.
  • the non-slip coating layer may have a glass transition temperature of at least about ⁇ 80 degrees Celsius (° C.), at least about ⁇ 70° C., and at least about ⁇ 65° C., and a glass transition temperature of no greater than about ⁇ 5° C., no greater than about ⁇ 15° C., and no greater than about ⁇ 25° C.
  • the non-slip coating layer 14 is formed of an aqueous solution that forms a coating layer having a glass transition temperature of at least about ⁇ 80 degrees Celsius (° C.), at least about ⁇ 70° C., and at least about ⁇ 65° C., and a glass transition temperature of no greater than about ⁇ 5° C., no greater than about ⁇ 15° C., and no greater than about ⁇ 25° C.
  • elastomeric non-slip coating layers Commercially available materials suitable for producing elastomeric non-slip coating layers include Butofan NS209, a carboxylated styrene-butadiene anionic dispersion available from BASF Corporation, Florham Park, N.J., and Hystretch elastomeric dispersions V-29, V-43, and V-60 available from Lubrizol Corporation, Wickliffe, Ohio. Ethylene-vinyl acetate (EVA) dispersions may also be used.
  • EVA Ethylene-vinyl acetate
  • Suitable materials for producing the non-slip coating layer 14 also include acrylates and acrylic polymers.
  • suitable materials for producing the non-slip coating layer 14 include pressure sensitive adhesives, such as acrylic adhesives—which may or may not include a tack modifying ingredient—repositionable adhesives, or hot melt acrylic adhesives.
  • acrylic adhesives which may or may not include a tack modifying ingredient—repositionable adhesives
  • hot melt acrylic adhesives can be produced with a variety of physical characteristics including both tacky and non-tacky characteristics.
  • the particular thickness of the non-slip coating layer 14 may vary depending on, for example, the material selected to form the non-slip coating layer 14 , and depending on the intended end use application for the abrasive article 10 .
  • a non-slip coating layer 14 formed of rubber or urethane base material may have a thickness of at least about 0.1 mil (2.5 micrometers), at least about 1 mil (25 micrometers), and at least about 10 mils (254 micrometers), and a thickness of no greater than about 50 mils (1270 micrometers), no greater than about 30 mils (762 micrometers), and no greater than about 25 mils (635 micrometers).
  • a non-slip coating layer 14 formed of an acrylic polymer coating may be thinner, and may have a thickness of at least about 0.1 (2.5 micrometers), at least about 0.5 (12.7 micrometers), and at least about 1 mil (25.4 micrometers), and a thickness of no greater than about 2 mils (50.8 micrometers), no greater than about 5 mils (127 micrometers), and no greater than about 10 mils (254 micrometers).
  • a non-slip coating layer 14 formed from a dried styrene-butadiene rubber dispersion or a dried latex dispersion may have a coating weight of at least about 1 gram/square meter (g/m 2 ) (0.24 grains/24 square inch (grains/24 in 2 )), at least about 3 g/m 2 (0.72 grains/24 in 2 ), or at least about 4 g/m 2 (0.96 grains/24 in 2 ), and a coating weight of no greater than about 20 g/m 2 (4.8 grains/24 in 2 ), no greater than about 15 g/m 2 (3.6 grains/24 in 2 ), or no greater than about 12 g/m 2 (2.9 grains/24in 2 ).
  • a suitable non-slip coating layer 14 may be produced using a pressure sensitive adhesive by coating a polymerizable pressure sensitive adhesive composition onto the backing layer 12 , and then polymerizing the pressure sensitive adhesive composition to produce a non-slip coating layer having the desired properties, or by coating a repositionable pressure sensitive adhesive onto the backing layer 12 .
  • the pressure sensitive adhesive is an acrylic hot melt adhesive that may be produced by, for example, providing a polymerizable liquid monomer mixture in a sealed pouch formed of, for example, ethylene vinyl acetate (EVA), at least partially polymerizing the liquid monomer mixture by, for example, exposing the liquid monomer mixture to actinic radiation (e.g., ultraviolet light), blending the partially polymerized liquid with the EVA material used to form the pouch, thereby forming a coatable pressure sensitive adhesive composition, and coating the pressure sensitive adhesive composition onto a backing layer 12 .
  • EVA ethylene vinyl acetate
  • the non-slip layer 14 is formed by further polymerizing the pressure sensitive adhesive to form a non-slip coating layer having the desired characteristics, such as a coating layer having a low level of tack, or no tack.
  • the degree of additional polymerization may vary, and will depend, for example, on the desired properties of the non-slip layer 14 . Further polymerization may be accomplished by, for example, exposing the pressure sensitive adhesive to additional UV light or by thermal polymerization in an amount sufficient to reduce the level of tack of the pressure sensitive adhesive to the desired level.
  • a suitable polymerizable liquid monomer mixture may include, for example, a mixture of 2 ethyl hexyl acrylate, butyl acrylate, methyl acrylate, and a photo-initiator such as Irgacure 651 available from Ciba-Geigy Corp. Hawthorne, N.Y.
  • a photo-initiator such as Irgacure 651 available from Ciba-Geigy Corp. Hawthorne, N.Y.
  • Optional additives such as isooctyl thioglycolate, hexanediol diacrylate, alphabenzophenone, and Irganox 1076 antioxidant available from Ciba Specialty Chemicals Corporation, Tarrytown, N.Y., may also be included in the polymerizable liquid monomer mixture.
  • the non-slip coating layer 14 can be applied as a liquid suspension, such as an aqueous dispersion, an aqueous emulsion such as a latex, or as a hot melt adhesive.
  • Liquids may be applied using a variety of known printing and/or coating techniques including, for example, roll coating (e.g., rotogravure coating), transfer roll coating, solvent coating, hot melt coating, spray coating, Meyer rod coating, and drop die coating.
  • roll coating e.g., rotogravure coating
  • Particularly desirable techniques for applying aqueous emulsions and dispersions include Meyer rod coating, rotogravure and transfer roll coating techniques. Such aqueous emulsions and dispersions are then allowed to dry to produce the non-slip coating layer 14 .
  • a particularly desirable technique for applying a hot melt adhesive, such as an acrylate hot melt adhesive, is drop die coating. Such a hot melt coated adhesive is then further polymerized to produce a non-slip coating layer 14 having the desired characteristics.
  • the non-slip coating layer 14 is provided with a surface texture.
  • a textured surface may be provided by applying the liquid emulsion or liquid dispersion to the backing layer 12 using, for example, a microcell foam roller or through spray coating.
  • a liquid emulsion or liquid dispersion is applied using a microcell foam roller to a coating weight of about 3 grains/24 square inch.
  • the liquid coating may then be dried, for example, in a forced air oven at a temperature of 225 degrees Fahrenheit for 5 minutes to produce the non-slip coating layer.
  • the non-slip coating 14 defines a generally planer outer surface 14 a of the sandpaper 10 opposite the make coat 16 and abrasive particles 18 . That is, the non-slip coating layer 14 defines a smooth outer surface that does not include a textured surface or a macroscopic three dimensional surface topography.
  • the coating layer 14 may be continuous, discontinuous, and/or applied in random or repeating patterns, such as dots and stripes.
  • the non-slip coating layer 14 may be clear. In this manner, any information or indicia printed on the backing 12 will remain visible through the non-slip coating layer 14 . In addition, the appearance of the sandpaper remains similar to the appearance of conventional sandpaper, to which users have become accustomed.
  • the outer surface 14 a of the non-slip coating layer 14 may include a regular patterned surface texture or geometry.
  • the patterned surface texture of the non-slip coating layer 14 outer surface 14 a may be such that the pattern inter-engages with itself when the sandpaper 10 of folded over onto itself. That is, the outer surface 14 a includes raised 14 a ′ and recessed 14 a ′′ regions that mate with each other when the outer surface 14 a is folded over onto itself.
  • the non-slip coating layer 14 may further comprise filler material or particles to provide the non-slip coating layer 14 outer surface 14 a with a rough or randomly textured surface. Such a rough or textured surface serves to enhance the traction properties of the non-slip coating layer 14 .
  • any adhesive make coat 16 may be used to adhere the abrasive particles 18 to the backing layer 12 .
  • “Make coat” refers to the layer of hardened resin over the backing layer 12 of the sandpaper 10 .
  • Suitable materials for the adhesive make coat 16 include, for example, phenolic resins, aminoplast resins having pendant ⁇ , ⁇ -unsaturated carbonyl groups, urethane resins, epoxy resins, ethylenically unsaturated resins, acrylated isocyanurate resins, urea-formaldehyde resins, isocyanurate resins, acrylated urethane resins, acrylated epoxy resins, bismaleimide resins, fluorene-modified epoxy resins, and combinations thereof.
  • the make coat 16 may be coated onto the backing layer 12 by any conventional technique, such as knife coating, spray coating, roll coating, rotogravure coating, curtain coating, and the like.
  • the sandpaper 10 may also include an optional size coat (not shown).
  • any abrasive particles 18 may be used with this disclosure.
  • Suitable abrasive particles include, for example, fused aluminum oxide, heat treated aluminum oxide, alumina-based ceramics, silicon carbide, zirconia, alumina-zirconia, garnet, emery, diamond, ceria, cubic boron nitride, ground glass, quartz, titanium diboride, sol gel abrasives and combinations thereof
  • the abrasive particles 18 can be either shaped (e.g., rod, triangle, or pyramid) or unshaped (i.e., irregular).
  • the term “abrasive particle” encompasses abrasive grains, agglomerates, or multi-grain abrasive granules.
  • the abrasive particles can be deposited onto the make coat 16 by any conventional technique such as electrostatic coating or drop coating.
  • the make coat 16 and/or the optional size coat may contain optional additives, such as fillers, fibers, lubricants, grinding aids, wetting agents, thickening agents, anti-loading agents, surfactants, pigments, dyes, coupling agents, photo-initiators, plasticizers, suspending agents, antistatic agents, and the like.
  • Possible fillers include calcium carbonate, calcium oxide, calcium metasilicate, alumina trihydrate, cryolite, magnesia, kaolin, quartz, and glass.
  • Fillers that can function as grinding aids include cryolite, potassium fluoroborate, feldspar, and sulfur. The amounts of these materials are selected to provide the properties desired, as is known to those skilled in the art.
  • the sandpaper 10 is a standard 9 ⁇ 11 inch sheet of sandpaper.
  • the sandpaper 10 may have a width of about 3 to about 4 inches, or of about 5 to about 6 inches, and a length of about 8 to about 10 inches, or about 10 to about 12 inches.
  • the present disclosure provides a package of sandpaper including a stack of sheets of sandpaper.
  • the stack may include at least 2 sheets, at least about 6 sheets, or at least about 10 sheets.
  • the abrasive article 10 may be made by providing a paper backing layer, coating an adhesive make coat on one major surface of the backing layer, at least partially embedding abrasive particles in the make coat, thereby forming an abrasive surface, dissolving a non-slip coating material, such as a mixture of rubber and tackifier, in a hydrocarbon solvent, such as toluene, thereby to form a coatable non-slip material, coating the non-slip material and solvent onto the surface of the backing layer opposite the make coat, and allowing the solvent to evaporate from the non-slip material, thereby forming a non-slip coating layer 14 on the backing layer 12 .
  • the non-slip coating layer 14 is said to be “solvent coated” onto the backing.
  • an aqueous emulsion or aqueous dispersion is coated onto the backing layer 12 opposite the make coat 16 , and is dried, thereby forming the non-slip coating layer 14 .
  • the abrasive article 10 may be made by providing a paper backing layer 12 , coating an adhesive make coat 16 on one major surface of the backing layer 12 , at least partially embedding abrasive particles 18 in the adhesive make coat 16 , thereby forming an abrasive surface, providing a non-slip material such as a mixture of rubber and tackifier, heating the non-slip material, thereby forming a coatable non-slip material, and coating the non-slip material onto the surface of the backing layer 12 opposite the make coat 16 , thereby forming a non-slip coating layer 14 .
  • the non-slip coating layer 14 may be coated onto the backing layer 12 using, for example, roll coating, hot melt coating, or drop die coating techniques.
  • the roller used to apply the coatable non-slip material is a foam roller, which imparts a surface texture to the non-slip coating layer.
  • a foam roller may be used to post treat the non-slip coating layer 14 after it has been coated onto the backing layer 12 , thereby imparting the non-slip coating layer with a surface texture.
  • an adhesive such as an acrylic hot melt adhesive, is coated onto the backing layer 12 opposite the make coat 16 , and is cured by, for example, polymerization or drying, thereby forming the non-slip coating layer 14 .
  • the order in which the non-slip coating layer 14 and made coat layer 16 are applied to the backing layer 12 may be varied. That is, the non-slip coating layer 14 may be applied to the backing layer 12 either before or after the make coat 16 is applied to the backing layer 12 .
  • the backing layer 12 , make coat 16 , and abrasive particles 18 may be provided in the form of a pre-formed (i.e., otherwise complete) abrasive sheet. That is, rather than providing a backing layer 12 , which is then coated with make coat 16 and provided with abrasive particles 18 to form an abrasive sheet, a pre-formed abrasive sheet including a backing, make coat and abrasive particles may be provided. The non-slip coating layer 14 can then be applied directly to the pre-formed abrasive sheet.
  • Suitable pre-formed abrasive sheets are available under the product designation 216U, from 3M Company, St. Paul, Minn. 216U is sandpaper having an A weight backing, a phenolic make coat, aluminum oxide abrasive particles, and a stearic acid supersize coating, which is provided to minimize loading.
  • the non-slip coating layer 14 may be applied to the backing layer 12 using, for example, solvent coating, roll coating, hot melt coating, drop die, or powder coating techniques.
  • a wide variety of commercially available conventional sandpaper constructions having a wide variety of backing materials e.g., papers, films, cloths
  • weights e.g., A, B, or C weight paper
  • abrasive particles may be coated with a non-slip coating according to the present disclosure.
  • the abrasive articles including the non-slip coating layer of the present disclosure display superior resistance to curling when immersed in water or subjected to humid environments.
  • the abrasive articles When tested in accordance with the Wet Curl test (described in the Examples section below), the abrasive articles preferably do not substantially curl.
  • Samples for this test method were prepared using a Type Six melt mixer with CAM blades from Brabender Instruments, Inc., South Hackensack, N.J.
  • the melt mixer was heated to 180° C. and the CAM blades were set to mix at a rate of 65 rpm.
  • Ingredients were added in the relative amounts described for the non-slip coating formulations in Table 1 to provide sample sizes of approximately 60 grams. After the contents were visually well mixed, usually lasting a period from 2-3 minutes, the mixture was then drained from the mixing bowl into an aluminum tray for analysis.
  • test material non-slip formulation
  • the top plate measured 20 mm in diameter while the bottom plate measured 100 mm in diameter.
  • the bottom plate was a Peltier temperature controlled plate that performed a temperature sweep from 190° C. to 80° C. in steps of 10° C. with an equilibrium of 60 seconds at each temperature step.
  • the top plate subjected each sample to a fixed 1.25% small amplitude oscillatory strain at a constant frequency of 10 Hz.
  • the magnitude of the axial force is proportional to the relative adhesion of the non-slip coating material to the top plate and is measured by a force transducer attached to the top plate of the rheometer and recorded.
  • Samples for this test method are placed in water under ambient conditions in a tin pan (approx. 1 inch of water) and soaked for approximately 5 minutes. Samples are promptly removed and the Coefficient of Friction is measured according to ASTM D 1894-08.
  • Tack is measured according to Probe Tack Test ASTM 2979-01.
  • Samples for this test method are provided or cut into 3 inch by 6 inch strips. Samples are placed in water under ambient conditions in a tin pan (approx. 1 inch of water) and soaked for approximately 5 minutes. Samples are visually inspected for curling while still in water. As used in reference to this test method, a sample does not substantially curl if the opposing ends are not drawn towards one another such that; a) neither of the opposing end edges reaches a location adjacent the center of the strip; and/or b) the opposing ends of the strip are generally coplanar.
  • 216U P150 sandpaper is a general purpose sandpaper having an A-weight paper backing, a phenolic resin coated on one side, and aluminum oxide abrasive particles at least partially embedded on the phenolic resin.
  • the second side (i.e., the non-abrasive side opposite the abrasive surface) of the sandpaper was then coated with one of the non-slip coating formulations to a thickness of about 4-5 mils.
  • the Dry Coefficient of Friction and Tack for the non-slip coatings of Examples E1-E8 were measured. As a control, the Dry Coefficient of Friction and Tack was also measured for 3M 216U P150 sandpaper. Dry Coefficient of Friction was also measured for Comparative Examples CE1-CE4. The results are summarized in Table 2.
  • the Relative Hot Melt Adhesion was measured for the non-slip formulations of Examples E6, E7, E9 and the Comparative Examples CE1-CE4 using the Relative Hot Melt Adhesion test method described above.
  • the evolution of this axial force for the samples tested is summarized in Table 3.
  • the negative sign of the force is in reference to its direction as a compressive force, i.e., meaning exerting a pull on the top plate.
  • the 80° C. is a relevant temperature because the non-slip coatings on the sandpaper typically will soften or melt and stick to power tools around that that temperature.
  • the less pull exerted (lower negative number) is an indication that there would be relatively low or no adhesion to a power tool surface.
  • Examples E9-E12 the second, non-abrasive side of 431Q sandpaper, available from by 3M Company, St. Paul, Minn., was coated with the non-slip coating formulation of Example E6 (prepared as above) to a thickness of about 4-5 mils.
  • 431Q sandpaper is a general-purpose sandpaper having a C-weight paper backing, a phenolic resin coated on one side, and silicon carbide abrasive particles at least partially embedded in the phenolic resin.
  • Examples E9-E10 feature 431Q, P240 sandpaper
  • Examples E11-E12 feature 431Q, P600 sandpaper.
  • Example E13 the second, non-abrasive side of 413Q, P400 sandpaper, available from by 3M Company, St. Paul, Minn., was coated with the non-slip coating formulation of Example E6 to a thickness of about 4-5 mils.
  • 413Q sandpaper is a general-purpose sandpaper having an A-weight paper backing, a phenolic resin coated on one side, and silicon carbide abrasive particles at least partially embedded in the phenolic resin.
  • a GATOR brand P320 waterproof sanding sheet and 413Q, P400 sandpaper served as Comparative Examples CE7 and CE8, respectively.
  • the Wet Curl was evaluated for E13, CE7, and CE8 using the Wet Curl test method described above. The results for the tested samples are depicted in FIG. 3 .

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CN115122247A (zh) * 2022-07-05 2022-09-30 凯诺建设有限公司 一种腻子打磨砂纸及使用该砂纸的腻子打磨装置

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US3402034A (en) * 1965-10-19 1968-09-17 Armour & Co Coated abrasive products
GB2314791B (en) * 1996-07-04 1999-09-01 Evode Ltd Polymeric coatings
US8662962B2 (en) * 2008-06-30 2014-03-04 3M Innovative Properties Company Sandpaper with non-slip coating layer and method of using
CN201702693U (zh) * 2010-06-17 2011-01-12 深圳市铭圣隆科技有限公司 防滑砂纸
CN103442852B (zh) * 2011-03-11 2016-08-24 3M创新有限公司 具有防滑涂层的粗砂纸
BR112013023250A2 (pt) * 2011-03-11 2016-12-20 3M Innovantive Properties Company folhas de lixa grossa, método de lixamento a mão de uma superície de trabalho e método para fabricação de um folha de lixa grossa
US9114505B2 (en) * 2011-06-20 2015-08-25 3M Innovative Properties Company Sandpaper with fibrous non-slip layer
CN204585002U (zh) * 2014-11-27 2015-08-26 江苏金研研磨有限公司 一种柔软绒毛砂纸

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