US20200206874A1 - Lay flat coated abrasive discs - Google Patents
Lay flat coated abrasive discs Download PDFInfo
- Publication number
- US20200206874A1 US20200206874A1 US16/714,215 US201916714215A US2020206874A1 US 20200206874 A1 US20200206874 A1 US 20200206874A1 US 201916714215 A US201916714215 A US 201916714215A US 2020206874 A1 US2020206874 A1 US 2020206874A1
- Authority
- US
- United States
- Prior art keywords
- mil
- abrasive article
- coated abrasive
- kpsi
- polymeric
- 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
Links
- 239000000203 mixture Substances 0.000 claims description 112
- 239000002245 particle Substances 0.000 claims description 57
- 229920000642 polymer Polymers 0.000 claims description 39
- 239000000463 material Substances 0.000 claims description 30
- -1 polyethylene Polymers 0.000 claims description 29
- 239000000758 substrate Substances 0.000 claims description 25
- 239000010432 diamond Substances 0.000 claims description 22
- 229910003460 diamond Inorganic materials 0.000 claims description 13
- 239000004698 Polyethylene Substances 0.000 claims description 11
- 229920000573 polyethylene Polymers 0.000 claims description 11
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 claims description 10
- 229920000058 polyacrylate Polymers 0.000 claims description 10
- 229910052582 BN Inorganic materials 0.000 claims description 8
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 8
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 claims description 8
- 229920001684 low density polyethylene Polymers 0.000 claims description 6
- 239000004702 low-density polyethylene Substances 0.000 claims description 6
- KCTAWXVAICEBSD-UHFFFAOYSA-N prop-2-enoyloxy prop-2-eneperoxoate Chemical compound C=CC(=O)OOOC(=O)C=C KCTAWXVAICEBSD-UHFFFAOYSA-N 0.000 claims description 6
- 229920000728 polyester Polymers 0.000 claims description 5
- QLZJUIZVJLSNDD-UHFFFAOYSA-N 2-(2-methylidenebutanoyloxy)ethyl 2-methylidenebutanoate Chemical compound CCC(=C)C(=O)OCCOC(=O)C(=C)CC QLZJUIZVJLSNDD-UHFFFAOYSA-N 0.000 claims description 4
- POYODSZSSBWJPD-UHFFFAOYSA-N 2-methylprop-2-enoyloxy 2-methylprop-2-eneperoxoate Chemical compound CC(=C)C(=O)OOOC(=O)C(C)=C POYODSZSSBWJPD-UHFFFAOYSA-N 0.000 claims description 4
- 229920006244 ethylene-ethyl acrylate Polymers 0.000 claims description 4
- 239000005042 ethylene-ethyl acrylate Substances 0.000 claims description 4
- 229920006225 ethylene-methyl acrylate Polymers 0.000 claims description 4
- 239000005043 ethylene-methyl acrylate Substances 0.000 claims description 4
- 229920001903 high density polyethylene Polymers 0.000 claims description 4
- 239000004700 high-density polyethylene Substances 0.000 claims description 4
- KUDUQBURMYMBIJ-UHFFFAOYSA-N 2-prop-2-enoyloxyethyl prop-2-enoate Chemical compound C=CC(=O)OCCOC(=O)C=C KUDUQBURMYMBIJ-UHFFFAOYSA-N 0.000 claims description 3
- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical compound CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 claims description 3
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 claims description 3
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 3
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 3
- 238000000034 method Methods 0.000 abstract description 10
- 239000011230 binding agent Substances 0.000 description 29
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 14
- 239000000470 constituent Substances 0.000 description 11
- 239000004593 Epoxy Substances 0.000 description 9
- 239000004925 Acrylic resin Substances 0.000 description 8
- 239000005977 Ethylene Substances 0.000 description 8
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 8
- 239000000654 additive Substances 0.000 description 8
- 239000003795 chemical substances by application Substances 0.000 description 8
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 7
- 230000008901 benefit Effects 0.000 description 7
- 229920001577 copolymer Polymers 0.000 description 7
- 239000000377 silicon dioxide Substances 0.000 description 7
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 6
- 239000003822 epoxy resin Substances 0.000 description 6
- 238000005498 polishing Methods 0.000 description 6
- 229920000647 polyepoxide Polymers 0.000 description 6
- 229920005989 resin Polymers 0.000 description 6
- 239000011347 resin Substances 0.000 description 6
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 5
- 239000000945 filler Substances 0.000 description 5
- 238000000227 grinding Methods 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 229920001296 polysiloxane Polymers 0.000 description 5
- 229920001897 terpolymer Polymers 0.000 description 5
- 230000009286 beneficial effect Effects 0.000 description 4
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 4
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 239000011353 cycloaliphatic epoxy resin Substances 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 239000000178 monomer Substances 0.000 description 4
- 229910010271 silicon carbide Inorganic materials 0.000 description 4
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 4
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 3
- MPIAGWXWVAHQBB-UHFFFAOYSA-N [3-prop-2-enoyloxy-2-[[3-prop-2-enoyloxy-2,2-bis(prop-2-enoyloxymethyl)propoxy]methyl]-2-(prop-2-enoyloxymethyl)propyl] prop-2-enoate Chemical compound C=CC(=O)OCC(COC(=O)C=C)(COC(=O)C=C)COCC(COC(=O)C=C)(COC(=O)C=C)COC(=O)C=C MPIAGWXWVAHQBB-UHFFFAOYSA-N 0.000 description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 3
- 229920000180 alkyd Polymers 0.000 description 3
- CDQSJQSWAWPGKG-UHFFFAOYSA-N butane-1,1-diol Chemical compound CCCC(O)O CDQSJQSWAWPGKG-UHFFFAOYSA-N 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 3
- 229920006267 polyester film Polymers 0.000 description 3
- 239000002002 slurry Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- QYEXBYZXHDUPRC-UHFFFAOYSA-N B#[Ti]#B Chemical compound B#[Ti]#B QYEXBYZXHDUPRC-UHFFFAOYSA-N 0.000 description 2
- 229910052580 B4C Inorganic materials 0.000 description 2
- 229920000742 Cotton Polymers 0.000 description 2
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 description 2
- BAPJBEWLBFYGME-UHFFFAOYSA-N Methyl acrylate Chemical compound COC(=O)C=C BAPJBEWLBFYGME-UHFFFAOYSA-N 0.000 description 2
- 229920002873 Polyethylenimine Polymers 0.000 description 2
- 229910052581 Si3N4 Inorganic materials 0.000 description 2
- 229910033181 TiB2 Inorganic materials 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- DAKWPKUUDNSNPN-UHFFFAOYSA-N Trimethylolpropane triacrylate Chemical compound C=CC(=O)OCC(CC)(COC(=O)C=C)COC(=O)C=C DAKWPKUUDNSNPN-UHFFFAOYSA-N 0.000 description 2
- 239000003082 abrasive agent Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 229910001610 cryolite Inorganic materials 0.000 description 2
- 239000002270 dispersing agent Substances 0.000 description 2
- 229910001651 emery Inorganic materials 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 239000002223 garnet Substances 0.000 description 2
- 239000000314 lubricant Substances 0.000 description 2
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 229920001179 medium density polyethylene Polymers 0.000 description 2
- 239000004701 medium-density polyethylene Substances 0.000 description 2
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 2
- AHHWIHXENZJRFG-UHFFFAOYSA-N oxetane Chemical compound C1COC1 AHHWIHXENZJRFG-UHFFFAOYSA-N 0.000 description 2
- 239000004014 plasticizer Substances 0.000 description 2
- 229920006254 polymer film Polymers 0.000 description 2
- ODGAOXROABLFNM-UHFFFAOYSA-N polynoxylin Chemical compound O=C.NC(N)=O ODGAOXROABLFNM-UHFFFAOYSA-N 0.000 description 2
- 229920002635 polyurethane Polymers 0.000 description 2
- 239000004814 polyurethane Substances 0.000 description 2
- 239000002243 precursor Substances 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 239000012763 reinforcing filler Substances 0.000 description 2
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 2
- 239000003381 stabilizer Substances 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- GTELLNMUWNJXMQ-UHFFFAOYSA-N 2-ethyl-2-(hydroxymethyl)propane-1,3-diol;prop-2-enoic acid Chemical compound OC(=O)C=C.OC(=O)C=C.OC(=O)C=C.CCC(CO)(CO)CO GTELLNMUWNJXMQ-UHFFFAOYSA-N 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- 229930185605 Bisphenol Natural products 0.000 description 1
- 229920002799 BoPET Polymers 0.000 description 1
- 229920010126 Linear Low Density Polyethylene (LLDPE) Polymers 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- 229920000459 Nitrile rubber Polymers 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 240000007594 Oryza sativa Species 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000005062 Polybutadiene Substances 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 229920002396 Polyurea Polymers 0.000 description 1
- 229920005830 Polyurethane Foam Polymers 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- 229920000297 Rayon Polymers 0.000 description 1
- DBMJMQXJHONAFJ-UHFFFAOYSA-M Sodium laurylsulphate Chemical compound [Na+].CCCCCCCCCCCCOS([O-])(=O)=O DBMJMQXJHONAFJ-UHFFFAOYSA-M 0.000 description 1
- 239000004141 Sodium laurylsulphate Substances 0.000 description 1
- 229920010741 Ultra High Molecular Weight Polyethylene (UHMWPE) Polymers 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- QYKIQEUNHZKYBP-UHFFFAOYSA-N Vinyl ether Chemical compound C=COC=C QYKIQEUNHZKYBP-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 239000002318 adhesion promoter Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- 125000005250 alkyl acrylate group Chemical group 0.000 description 1
- 229920003180 amino resin Polymers 0.000 description 1
- 230000000844 anti-bacterial effect Effects 0.000 description 1
- 239000002216 antistatic agent Substances 0.000 description 1
- 239000003899 bactericide agent Substances 0.000 description 1
- 229920006378 biaxially oriented polypropylene Polymers 0.000 description 1
- 239000011127 biaxially oriented polypropylene Substances 0.000 description 1
- 239000004841 bisphenol A epoxy resin Substances 0.000 description 1
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 1
- 239000008116 calcium stearate Substances 0.000 description 1
- 235000013539 calcium stearate Nutrition 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000011195 cermet Substances 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 239000007822 coupling agent Substances 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 150000004292 cyclic ethers Chemical class 0.000 description 1
- NZNMSOFKMUBTKW-UHFFFAOYSA-N cyclohexanecarboxylic acid Chemical compound OC(=O)C1CCCCC1 NZNMSOFKMUBTKW-UHFFFAOYSA-N 0.000 description 1
- 238000007872 degassing Methods 0.000 description 1
- 125000004386 diacrylate group Chemical group 0.000 description 1
- QDOXWKRWXJOMAK-UHFFFAOYSA-N dichromium trioxide Chemical compound O=[Cr]O[Cr]=O QDOXWKRWXJOMAK-UHFFFAOYSA-N 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 238000010410 dusting Methods 0.000 description 1
- 239000000975 dye Substances 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 150000002118 epoxides Chemical class 0.000 description 1
- HGVPOWOAHALJHA-UHFFFAOYSA-N ethene;methyl prop-2-enoate Chemical compound C=C.COC(=O)C=C HGVPOWOAHALJHA-UHFFFAOYSA-N 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- IVJISJACKSSFGE-UHFFFAOYSA-N formaldehyde;1,3,5-triazine-2,4,6-triamine Chemical compound O=C.NC1=NC(N)=NC(N)=N1 IVJISJACKSSFGE-UHFFFAOYSA-N 0.000 description 1
- MSYLJRIXVZCQHW-UHFFFAOYSA-N formaldehyde;6-phenyl-1,3,5-triazine-2,4-diamine Chemical class O=C.NC1=NC(N)=NC(C=2C=CC=CC=2)=N1 MSYLJRIXVZCQHW-UHFFFAOYSA-N 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000000417 fungicide Substances 0.000 description 1
- 150000003949 imides Chemical class 0.000 description 1
- 239000003999 initiator Substances 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 239000012948 isocyanate Substances 0.000 description 1
- 150000002513 isocyanates Chemical class 0.000 description 1
- ZFSLODLOARCGLH-UHFFFAOYSA-N isocyanuric acid Chemical compound OC1=NC(O)=NC(O)=N1 ZFSLODLOARCGLH-UHFFFAOYSA-N 0.000 description 1
- 239000004816 latex Substances 0.000 description 1
- 229920000126 latex Polymers 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- YDKNBNOOCSNPNS-UHFFFAOYSA-N methyl 1,3-benzoxazole-2-carboxylate Chemical compound C1=CC=C2OC(C(=O)OC)=NC2=C1 YDKNBNOOCSNPNS-UHFFFAOYSA-N 0.000 description 1
- WYBKKXCISATIAS-UHFFFAOYSA-N methyl 7-oxabicyclo[4.1.0]heptane-3-carboxylate 7-oxabicyclo[4.1.0]heptane Chemical compound C1CCC2OC2C1.COC(=O)C1CCC2OC2C1 WYBKKXCISATIAS-UHFFFAOYSA-N 0.000 description 1
- QCGKUFZYSPBMAY-UHFFFAOYSA-N methyl 7-oxabicyclo[4.1.0]heptane-4-carboxylate Chemical compound C1C(C(=O)OC)CCC2OC21 QCGKUFZYSPBMAY-UHFFFAOYSA-N 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- SLCVBVWXLSEKPL-UHFFFAOYSA-N neopentyl glycol Chemical compound OCC(C)(C)CO SLCVBVWXLSEKPL-UHFFFAOYSA-N 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 229920003986 novolac Polymers 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- 239000003002 pH adjusting agent Substances 0.000 description 1
- 239000011238 particulate composite Substances 0.000 description 1
- 230000037361 pathway Effects 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920002857 polybutadiene Polymers 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 125000002924 primary amino group Chemical group [H]N([H])* 0.000 description 1
- 239000002964 rayon Substances 0.000 description 1
- 239000012758 reinforcing additive Substances 0.000 description 1
- 229920003987 resole Polymers 0.000 description 1
- 230000000284 resting effect Effects 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 235000019333 sodium laurylsulphate Nutrition 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 229920003048 styrene butadiene rubber Polymers 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 239000000375 suspending agent Substances 0.000 description 1
- 239000013501 sustainable material Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
- 230000009974 thixotropic effect Effects 0.000 description 1
- XOLBLPGZBRYERU-UHFFFAOYSA-N tin dioxide Chemical compound O=[Sn]=O XOLBLPGZBRYERU-UHFFFAOYSA-N 0.000 description 1
- 229910001887 tin oxide Inorganic materials 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 description 1
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 239000004636 vulcanized rubber Substances 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
- 239000000080 wetting agent Substances 0.000 description 1
- 229910052882 wollastonite Inorganic materials 0.000 description 1
- 239000010456 wollastonite Substances 0.000 description 1
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 1
Images
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
- B24D3/02—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 bonding agent
- B24D3/20—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 bonding agent and being essentially organic
- B24D3/28—Resins or natural or synthetic macromolecular compounds
-
- 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
Definitions
- the present invention relates generally to coated abrasive articles that lay flat, such as coated abrasive discs, as well as methods of making and using said coated abrasive articles.
- Abrasive articles such as coated abrasives, are used in various industries to machine work pieces, such as by lapping, grinding, and polishing.
- Surface processing using abrasive articles spans a wide industrial scope from initial coarse material removal to high precision finishing and polishing of surfaces at a submicron level.
- FIG. 1 is an illustration of an embodiment of a coated abrasive article (a coated abrasive disc) that lays flat.
- FIG. 2 is an illustration of a cross sectional view of the coated abrasive article embodiment of FIG. 1 and shows an abrasive layer disposed directly in contact with a layer of polymeric polyethylene composition.
- FIG. 3 is a flowchart of an embodiment of a method of making a coated abrasive article that lays flat.
- FIG. 4 is an illustration of an abrasive disc embodiment laying flat.
- FIG. 5 is an illustration of another abrasive disc embodiment laying flat.
- FIG. 6 is a photograph comparing the curvature of a sample abrasive disc embodiment 604 and a conventional abrasive disc 602 where the abrasive side of both abrasive discs faces upward.
- FIG. 7 is a photograph comparing the curvature of a sample abrasive disc embodiment 704 and a conventional abrasive disc 702 where the backing side of both abrasive discs faces upward.
- the term “averaged,” when referring to a value, is intended to mean an average, a geometric mean, or a median value.
- the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” or any other variation thereof, are intended to cover a non-exclusive inclusion.
- a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but can include other features not expressly listed or inherent to such process, method, article, or apparatus.
- the phrase “consists essentially of” or “consisting essentially of” means that the subject that the phrase describes does not include any other components that substantially affect the property of the subject.
- “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
- references to values stated in ranges include each and every value within that range.
- references to values stated in ranges include each and every value within that range.
- the terms “about” or “approximately” precede a numerical value such as when describing a numerical range, it is intended that the exact numerical value is also included.
- a numerical range beginning at “about 25” is intended to also include a range that begins at exactly 25.
- references to values stated as “at least about,” “greater than,” “less than,” or “not greater than” can include a range of any minimum or maximum value noted therein.
- average particle diameter can be reference to an average, mean, or median particle diameter, also commonly referred to in the art as D50.
- FIG. 1 shows an illustration of a cross section of an embodiment of a coated abrasive article 100 .
- the coated abrasive article can include an abrasive layer 103 disposed on a backing material 101 (also called herein a “backing”).
- the backing material 101 can comprise a backing substrate 105 having a first major surface 109 and a second major surface 107 , wherein a layer of a polymeric front coat composition 111 (also called herein a “front coat”) is disposed on the first major surface 109 of the backing substrate, and wherein a layer of polymeric back coat composition 113 (also called herein a “back coat”) is disposed on the second major surface 107 of the backing substrate.
- the abrasive layer can include a plurality of abrasive particles 117 dispersed on or in a layer of polymeric binder composition 115 (also called herein a “make coat”).
- the layer of polymeric binder composition 115 can be disposed in direct contact with the polymeric front coat composition 111 .
- a layer of polymeric size coat composition 119 (also called herein a “size coat”) can be disposed over the polymeric binder composition 115 and abrasive particles 117 .
- an optional layer of polymeric supersize coat composition (not shown) can be disposed over the size coat composition 119 .
- the coated abrasive article 100 may further include a tool attachment layer (not shown) located opposite the abrasive layer and disposed in contact with the polymeric back coat composition 113 .
- FIG. 2 shows an illustration of a coated abrasive article 200 embodiment.
- the coated abrasive article 200 can include a body 201 that, in a particular embodiment, can be generally disc shaped.
- Abrasive particles 203 can be disposed on the working surface (also called herein the “abrasive surface” or “top surface”) of the abrasive article.
- the coated abrasive article 200 can be configured to be removably engaged with a power sanding tool (not depicted) such as a random orbit sander or other type of powered disc sander.
- FIG. 3 is an illustration of a flowchart of an embodiment of a method 300 of making a coated abrasive article having curl resistance and that lays flat.
- Step 302 includes disposing a layer of a polymeric front coat composition (also called herein a “front coat”) on a first major surface of a backing substrate.
- Step 304 includes disposing a layer of a polymeric back coat composition (also called herein a “back coat”) on a second major surface of the backing substrate.
- step 302 and step 304 can be accomplished at the same time.
- step 302 and step 304 can be accomplished separately.
- Step 306 includes disposing a layer of a polymeric make coat composition (also called herein a “make coat”) on the front coat.
- Step 308 includes disposing a plurality of abrasive particles on or in the make coat.
- Step 310 includes disposing a polymeric size coat composition (also called herein a “size coat”) over the abrasive particles and the make coat to form an abrasive article.
- the abrasive article can be used as a polishing film, a polishing belt, or converted (i.e., cut) into different shapes, such as discs, sheets, or other shapes.
- Step 312 includes cutting the abrasive article into a plurality of abrasive discs.
- a tool attachment layer can be disposed on the back coat.
- FIG. 4 is an illustration of an abrasive disc embodiment laying flat.
- laying flat means that when an abrasive disc is placed at rest on a flat surface that the disc has a curvature where the height (h) of the disc (i.e., the highest point of the disc) is less than or equal to 10% of the diameter of the disc. For instance, if a disc has a diameter (D) of 5 inches, the disc will be considered to lay flat if the height of the disc is equal to 0.5 inches or less.
- the curvature of the disc is such that the height of the center of the disc is elevated, but is less than 10% of the diameter of the disc.
- FIG. 5 is an illustration of another abrasive disc embodiment laying flat. As shown in FIG. 5 , the curvature of the disc is such that the highest point(s) (i.e., the height) of the disc is located at the elevated edge(s) of the disc, but is less than 10% of the diameter of the disc.
- FIG. 6 is a photograph showing an oblique downward view comparing the curvature of a sample abrasive disc embodiment 604 and a conventional abrasive disc 602 .
- the abrasive surface of each abrasive disc faces upward away from the flat surface upon which the abrasive disc rests.
- the sample abrasive disc 604 lays flat and has a curvature where the height of the disc is less than 10% of the diameter of the disc.
- the comparative abrasive disc 602 does not lay flat.
- FIG. 7 is a photograph showing an oblique downward view comparing the curvature of a sample abrasive disc embodiment 704 and a conventional abrasive disc 702 .
- the back surface (non abrasive surface) of each abrasive disc faces upward away from the flat surface upon which the abrasive disc rests.
- the sample abrasive disc 704 lays flat and has a curvature where the height of the disc is less than 10% of the diameter of the disc.
- the comparative abrasive disc 702 does not lay flat.
- the backing material 101 (“backing”) comprises a backing substrate 105 having a first major surface 109 (“first side”) and a second major surface 107 (“second side”), wherein a layer of a polymeric front coat composition 111 (also called herein a “front coat”) is disposed on the first major surface 109 of the backing substrate, and wherein a layer of polymeric back coat composition 113 (also called herein a “back coat”) is disposed on the second major surface 107 of the backing substrate.
- the backing material 101 can be beneficially flexible but also is resistant to curling and lays flat when at rest.
- the backing material 101 can comprise a proper combination of desired physical, chemical, mechanical, and/or performance properties and/or features to produce advantageous abrasive performance in combination with abrasive particles as described in greater detail herein.
- the backing substrate can comprise a polymeric film, such as polyolefin film (e.g., polypropylene including biaxially oriented polypropylene), a polyester film (e.g., polyethylene terephthalate), a polyamide film, or a cellulose ester film; a metal foil; a mesh; a foam (e.g., natural sponge material or polyurethane foam); a cloth (e.g., cloth made from fibers or yarns comprising polyester, nylon, silk, cotton, poly-cotton, rayon, or combinations thereof); a paper; a vulcanized paper; a vulcanized rubber; a vulcanized fiber; a nonwoven material; a combination thereof.
- polyolefin film e.g., polypropylene including biaxially oriented polypropylene
- polyester film e.g., polyethylene terephthalate
- a polyamide film e.g., polyamide film, or a cellulose ester film
- metal foil e
- the polymeric film can be a surface energy modified film, such as a primed film, a corona treated film, a plasma treated film, a chemically treated film, or a combination thereof.
- the backing substrate can comprise a polyester film that has been chemically primed and corona treated or plasma treated.
- Suitable chemical primers can include imide type primers, such as polyethylene imine, and the like.
- the backing substrate can have a surface energy in a beneficial range.
- the surface energy of the film can be not less than 5 dyne, such as at least 10 dyne, at least 20 dyne, at least 30 dyne, at least 40 dyne, at least 45 dyne or at least 50 dyne.
- the surface energy can be not greater than 100 dyne, such as not greater than 90 dyne, not greater than 80 dyne, not greater than 70 dyne, not greater than 65 dyne, or not greater than 60 dyne.
- the amount of surface energy can be within a range comprising any pair of the previous upper and lower limits.
- the polymeric film can have an amount of surface energy not less than 5 dyne to not greater than 100 dyne, such as 20 dyne to 90 dyne, such as 30 dyne to 80 dyne, such as 40 dyne to 70 dyne, or 50 dyne to 60 dyne.
- the backing substrate can have a thickness in a beneficial range.
- the thickness of the film can be not less than 1 mil, such as at least 2 mil, at least 2.5 mil, at least 3 mil, at least 3.5 mil, at least 4 mil, or at least 4.5 mil.
- the thickness can be not greater than 9 mil, such as not greater than 8 mil, not greater than 7.5 mil, not greater than 7 mil, not greater than 6.5 mil, or not greater than 6 mil.
- the amount of thickness can be within a range comprising any pair of the previous upper and lower limits.
- the polymeric film can have an amount of thickness not less than 1 mil to not greater than 9 mil, such as 2 mil to 8 mil, such as 2.5 mil to 7.5 mil, such as 3 mil to 7 mil, or 50 mil to 60 mil.
- a layer of a polymeric front coat composition 111 is disposed on the first major surface 109 of the backing substrate.
- the polymeric front coat composition can comprise a polyethylene composition.
- the polyethylene composition can comprise a low density polyethylene (LDPE), a linear low-density polyethylene (LLDPE), a high-density polyethylene (HDPE), a medium-density polyethylene (MDPE), or an ultra-high-molecular-weight polyethylene (UHMWPE).
- the polymeric front coat composition comprises a low density polyethylene.
- a layer of polymeric back coat composition 113 is disposed on the second major surface 107 of the backing substrate.
- the polymeric back coat composition can comprise an acrylate composition.
- the acrylate composition can comprise an ethyl acrylate, an ethylene acrylate, an ethylene-ethyl acrylate (EEA), a methyl acrylate, an ethylene methyl acrylate (EMA) copolymer, a butyl acrylate, a copolymer of ethylene and butyl acrylate (EBA), an ethylene acrylic ester terpolymer (i.e., a terpolymer of ethylene, acrylic ester, and maleic anhydride), or a combination thereof.
- the back coat composition comprises a mixture of 1) a copolymer of ethylene and butyl acrylate (EBA), and 2) an ethylene acrylic ester terpolymer (i.e., a terpolymer of ethylene, acrylic ester, and maleic anhydride).
- EBA ethylene and butyl acrylate
- ethylene acrylic ester terpolymer i.e., a terpolymer of ethylene, acrylic ester, and maleic anhydride
- the abrasive layer can include a plurality of abrasive particles 117 dispersed on or in a layer of polymeric binder 115 (“make coat”).
- the abrasive particles can be blended together with the polymeric binder to form an abrasive slurry wherein the abrasive particles are dispersed throughout the binder formulation.
- the polymeric binder composition can be coated onto the backing material and the abrasive particles then applied over the binder composition.
- patterns can be formed in the abrasive layer by molding, pressing, or tooling of the abrasive layer.
- Abrasive particles can include alumina, silicon carbide, silica, ceria, and harder, high performance superabrasive particles such as cubic boron nitride and diamond.
- the abrasive particles can be essentially single phase inorganic materials, mixed phase materials, or combinations thereof. Additionally, the abrasive particles can include composite particulate materials, such as aggregates, which can be formed through slurry processing pathways that include removal of the liquid carrier through volatilization or evaporation, leaving behind unfired (“green”) aggregates, that can optionally undergo high temperature treatment (i.e., firing, sintering) to form usable, fired aggregates. Further, the abrasive layer can include engineered abrasives including macrostructures and particular three-dimensional structures.
- the abrasive particles can be formed of any one of or a combination of abrasive particles, including silica, alumina (ceramic, fused, or sintered), zirconia, zirconia/alumina oxides, silicon carbide, garnet, diamond, cubic boron nitride, silicon nitride, ceria, titanium dioxide, titanium diboride, boron carbide, tin oxide, tungsten carbide, titanium carbide, iron oxide, chromia, flint, emery.
- silica silica, alumina (ceramic, fused, or sintered), zirconia, zirconia/alumina oxides, silicon carbide, garnet, diamond, cubic boron nitride, silicon nitride, ceria, titanium dioxide, titanium diboride, boron carbide, tin oxide, tungsten carbide, titanium carbide, iron oxide, chromia, flint,
- the abrasive particles can be selected from a group consisting of silica, alumina, zirconia, silicon carbide, silicon nitride, boron nitride, garnet, diamond, co-fused alumina zirconia, ceria, titanium diboride, boron carbide, flint, emery, alumina nitride, and a blend thereof. Particular embodiments have been created by use of abrasive particles comprised of diamond.
- the abrasive particles can be diamond particles (also referred to herein as “diamonds”), cubic boron nitride particles, or combinations thereof.
- the abrasive particles comprise diamonds.
- the diamonds can be monocrystalline, polycrystalline, or a combination thereof.
- the diamonds can be natural diamonds, synthetic diamonds, metal coated diamonds, resin coated diamonds, or combinations thereof.
- the abrasive particles can be loose diamonds, diamond agglomerates, diamond aggregates, or a combination thereof.
- superabrasive particles include cubic boron nitride and diamond particles. These superabrasive particles can be natural (e.g. natural diamond) or synthetic (e.g. cubic boron nitride and synthetic diamond) products. The superabrasive particles may have a blocky shape associated with them or alternatively, a needle-like shape. The superabrasive particles may be surface coated or not surface coated. In an embodiment, a blend of superabrasive particles and conventional abrasive particles (e.g. alumina, silicon carbide, ceria, and silica) can be used.
- conventional abrasive particles e.g. alumina, silicon carbide, ceria, and silica
- the abrasive particles can have a particular shape, such as a rod, a triangle, a pyramid, a cone, a solid sphere, a hollow sphere, or the like. Alternatively, the abrasive particles can be randomly shaped.
- the abrasive particles can be in a beneficial size range, conform to a beneficial size distribution, or a combination thereof.
- the abrasive particles can have an average particle size of not less than 1 micron, such as at least 2 micron, at least 3 micron, at least 5 micron, at least 10 micron, at least 15 micron, at least 20 micron, or at least 25 micron.
- the average particle size can be not greater than 500 micron, such as not greater than 400 micron, not greater than 300 micron, not greater than 200 micron, not greater than 150 micron, or not greater than 125 micron.
- the average particle size can be within a range comprising any pair of the previous upper and lower limits.
- the abrasive particles can have an average particle size not less than 5 micron to not greater than 250 micron, such as 10 micron to 200 micron, such as 15 micron to 150 micron, such as 20 micron to 125 micron.
- a layer of polymeric binder composition 115 can be disposed in direct contact with the polymeric front coat composition 111 .
- the polymeric binder composition 115 can be comprised of a single polymer or a blend of polymers.
- the binder composition can be formed from an epoxy composition, an acrylic composition, a phenolic composition, a polyurethane composition, a urea formaldehyde composition, a polysiloxane composition, or combinations thereof.
- the binder composition can include active filler particles, additives, or a combination thereof, as described herein.
- the binder composition generally includes a polymer matrix, which binds abrasive particles to the backing or to a compliant coat, if such a compliant coat is present.
- the binder composition is formed of cured binder composition.
- the binder composition includes a polymer component and a dispersed phase.
- the binder composition can include one or more reaction constituents or polymer constituents for the preparation of a polymer.
- a polymer constituent can include a monomeric molecule, a polymeric molecule, or a combination thereof.
- the binder composition can further comprise components selected from the group consisting of solvents, plasticizers, chain transfer agents, catalysts, stabilizers, dispersants, curing agents, reaction mediators and agents for influencing the fluidity of the dispersion.
- the polymer constituents can form thermoplastics or thermosets.
- the polymer constituents can include monomers and resins for the formation of polyurethane, polyurea, polymerized epoxy, polyester, polyimide, polysiloxanes (silicones), polymerized alkyd, styrene-butadiene rubber, acrylonitrile-butadiene rubber, polybutadiene, or, in general, reactive resins for the production of thermoset polymers.
- Another example includes an acrylate or a methacrylate polymer constituent.
- the precursor polymer constituents are typically curable organic material (i.e., a polymer monomer or material capable of polymerizing or crosslinking upon exposure to heat or other sources of energy, such as electron beam, ultraviolet light, visible light, etc., or with time upon the addition of a chemical catalyst, moisture, or other agent which cause the polymer to cure or polymerize).
- a curable organic material i.e., a polymer monomer or material capable of polymerizing or crosslinking upon exposure to heat or other sources of energy, such as electron beam, ultraviolet light, visible light, etc., or with time upon the addition of a chemical catalyst, moisture, or other agent which cause the polymer to cure or polymerize.
- a precursor polymer constituent example includes a reactive constituent for the formation of an amino polymer or an aminoplast polymer, such as alkylated urea-formaldehyde polymer, melamine-formaldehyde polymer, and alkylated benzoguanamine-formaldehyde polymer; acrylate polymer including acrylate and methacrylate polymer, alkyl acrylate, acrylated epoxy, acrylated urethane, acrylated polyester, acrylated polyether, vinyl ether, acrylated oil, or acrylated silicone; alkyd polymer such as urethane alkyd polymer; polyester polymer; reactive urethane polymer; phenolic polymer such as resole and novolac polymer; phenolic/latex polymer; epoxy polymer such as bisphenol epoxy polymer; isocyanate; isocyanurate; polysiloxane polymer including alkylalkoxysilane polymer; or reactive vinyl polymer.
- the binder composition can include
- the binder composition can include epoxy constituents and acrylic constituents that when cured form an epoxy/acrylic hybrid polymer.
- the binder composition can comprise a butyl acrylate polymer.
- the binder composition can comprise a cycloaliphatic epoxy resin, a di-acrylate resin, or a combination thereof.
- the binder composition can comprise a hydrogenated diphenylolpropane (DPP) epoxy resin, an oxetane resin (4-member cyclic ether), a bisphenol A Epoxy Diacrylate resin (diacrylate ester of a bisphenol A epoxy resin), a propoxylated neopentyl glycol diacrylate resin, or combinations thereof.
- DPP diphenylolpropane
- layer of polymeric size coat composition 119 can be disposed over the polymeric binder composition 115 and abrasive particles 117 .
- the size coat composition 119 can be the same as or different from the polymeric binder composition 115 of the abrasive layer 103 (i.e., the size coat composition can be the same as or different than the make coat composition).
- the size coat composition can include one or more fillers, additives, or a combination thereof.
- the size coat composition 119 can comprise an epoxy resin, an acrylic resin, an acrylate resin, an epoxy acrylate resin, or a combination thereof.
- the size coat composition can comprise a reinforcing additive, such as amorphous silica.
- the size coat composition can comprise a cycloaliphatic epoxy resin, an epoxide, a diepoxide, a butanediol, a triacrylate, a hexaacrylate, a cyclohexylcarboxylate, or a combination thereof.
- the size coat composition can comprise a silica reinforced cycloaliphatic epoxy resin, an aliphatic epoxidized butanediol, trimethylolpropane triacrylate (TMPTA), dipentaerythritol hexaacrylate (DPHA), (3,4-epoxycyclohexane) methyl 3,4-epoxycyclohexylcarboxylate, or a combination thereof.
- TMPTA trimethylolpropane triacrylate
- DPHA dipentaerythritol hexaacrylate
- 3,4-epoxycyclohexane methyl 3,4-epoxycyclohexylcarboxylate
- the size coat composition can include 5 wt % to 45 wt % of a reinforcing filler, such 10 wt % to 35 wt % of a reinforcing filler.
- the coated abrasive article 100 can optionally comprise a layer of supersize coat composition (not shown) disposed on the size coat composition 119 .
- the supersize coat composition can be the same as or different from the polymeric binder composition 115 of the abrasive layer 103 and can be same as or different than the size coat composition 119 disposed thereon.
- the supersize coat composition may comprise an anti-loading agent (such as a stearate, such as a metal stearate, such as zinc stearate or calcium stearate) or a grinding aid (such as cryolite, potassium borofluorate), or a combination thereof.
- the front coat composition 111 , the back coat composition 113 , the binder composition 115 , the size coat composition 119 , or the supersize coat composition can include one or more additives.
- Additives can be available in an amount of 0 wt % to 10 wt % of any polymer layer (i.e., make coat layer, size coat layer, or supersize layer).
- Suitable additives can include grinding aids, fibers, lubricants, wetting agents, thixotropic materials, surfactants, thickening agents, pigments, dyes, antistatic agents, coupling agents, plasticizers, suspending agents, pH modifiers, adhesion promoters, lubricants, bactericides, fungicides, flame retardants, degassing agents, anti-dusting agents, dual function materials, initiators, chain transfer agents, stabilizers, dispersants, reaction mediators, colorants, and defoamers.
- the amounts of these additive materials can be selected to provide the properties desired.
- These optional additives can be present in any part of the overall system of the coated abrasive product according to embodiments of the present disclosure.
- Suitable grinding aids can be inorganic based; such as halide salts, for example cryolite, wollastonite, and potassium fluoroborate; or organic based, such as sodium lauryl sulphate, or chlorinated waxes, such as polyvinyl chloride.
- the grinding aid can be an environmentally sustainable material.
- the abrasive article can optionally include a tool attachment layer.
- the coated abrasive article 100 includes a tool attachment layer (not shown) that can be used to removably engage the coated abrasive article 100 with a power tool, such as a rotary sander.
- the tool attachment layer can include an adhesive.
- the tool attachment layer can include a mechanical fastener.
- the mechanical fastener can include a hook fastener, a loop fastener, or a combination thereof that is configured to removably engage with a corresponding mechanical fastener on the tool on which the coated abrasive article 100 is intended to be disposed during abrasive operations.
- Embodiment 1 A coated abrasive article comprising: an abrasive layer disposed on a backing material; wherein the backing material comprises: a backing substrate having a first side and a second side, and a layer of polymeric polyethylene composition disposed on the first side of the backing substrate; wherein the abrasive layer is disposed directly in contact with the polymeric polyethylene composition.
- Embodiment 2 The coated abrasive article of embodiment 1, wherein the coated abrasive article lays flat.
- Embodiment 3 The coated abrasive article of embodiment 1, wherein the coated abrasive article has a curvature of not greater than 10% of the diameter of the abrasive article.
- Embodiment 4 The coated abrasive article of embodiment 1, wherein the abrasive layer comprises a make coat or a size coat having a Young's modulus (stiffness) of at least 150 kpsi, such as at least 200 kpsi, at least 250 kpsi, at least 300 kpsi, at least 350 kpsi, at least 400 kpsi, at least 450 kpsi, or at least 500 kpsi.
- a Young's modulus stiffness
- Embodiment 5 The coated abrasive article of embodiment 4, wherein the abrasive layer comprises a make coat or a size coat having a Young's modulus (stiffness) of not greater than 900 kpsi, such as not greater than 850 kpsi, not greater than 800 kpsi, not greater than 750 kpsi, not greater than 700 kpsi, not greater than 650 kpsi, or not greater than 600 kpsi.
- a Young's modulus stiffness
- Embodiment 6 The coated abrasive article of embodiment 1, wherein the polymeric polyethylene composition comprises low density polyethylene, high density polyethylene, or a combination thereof.
- Embodiment 7 The coated abrasive article of embodiment 1, wherein the layer of polymeric polyethylene composition comprises a thickness of at least 0.25 mil to not greater than 0.5 mil, such as at least 1 mil to not greater than 3 mil, or at least 1.5 mil to not greater than 2.5 mil.
- Embodiment 8 The coated abrasive article of embodiment 1, further comprising a layer of polymeric acrylate composition disposed on a second side of the backing substrate.
- Embodiment 9 The coated abrasive article of embodiment 8, wherein the polymeric acrylate composition comprises ethyl acrylate, ethylene acrylate, ethylene-methyl acrylate, ethylene-ethyl acrylate, or a combination thereof.
- Embodiment 10 The coated abrasive article of embodiment 8, wherein the layer of polymeric acrylate composition comprises a thickness of at least 0.1 mil to not greater than 3 mil, such as at least 0.25 mil to not greater than 2.5 mil, or at least 0.5 mil to not greater than 2 mil.
- Embodiment 11 The coated abrasive article of embodiment 1, wherein the backing substrate comprises a polymeric film.
- Embodiment 12 The coated abrasive article of embodiment 11, wherein the polymeric film comprises a polyester film.
- Embodiment 13 The coated abrasive article of embodiment 11, wherein the polymeric film comprises polyethylene terephthalate.
- Embodiment 14 The coated abrasive article of embodiment 11, wherein the polymeric film comprises a thickness of at least 1 mil to not greater than 10 mil, such as at least 2 mil to not greater than 8 mil, at least 3 mil to not greater than 7 mil, or at least 4 mil to not greater than 6 mil.
- Embodiment 15 The coated abrasive article of embodiment 11, wherein the polymeric film comprises a surface energy of at least 40 dyne/cm 2 , such as at least 45 dyne/cm 2 .
- Embodiment 16 The coated abrasive article of embodiment 15, wherein the polymeric film is corona treated.
- Embodiment 17 The coated abrasive article of embodiment 1, wherein the abrasive layer comprises a polymeric make coat composition and abrasive particles disposed in the make coat composition.
- Embodiment 18 The coated abrasive article of embodiment 17, wherein the make coat composition comprises an epoxy acrylate polymer, an epoxy methacrylate polymer, a butyl acrylate polymer, or a combination thereof.
- Embodiment 19 The coated abrasive article of embodiment 17, wherein the make coat composition further comprises a filler.
- Embodiment 20 The coated abrasive article of embodiment 17, wherein the abrasive layer further comprises a polymeric size coat composition disposed on the make coat composition and abrasive particles.
- Embodiment 21 The coated abrasive article of embodiment 17, wherein the size coat composition comprises an epoxy acrylate polymer, an epoxy methacrylate polymer, a butyl acrylate polymer, or a combination thereof.
- Embodiment 22 The coated abrasive article of embodiment 17, wherein the make coat composition further comprises a filler.
- Embodiment 23 The coated abrasive article of embodiment 17, wherein the abrasive particles comprise diamond, cubic boron nitride, or a combination thereof.
- Embodiment 24 The coated abrasive article of embodiment 23, wherein the abrasive particles comprise a grit size of 5 microns to 500 microns.
- Sample coated abrasive film was prepared as described herein.
- a backing material was prepared by applying a front coat and a back coat to a backing substrate. Details of the backing material are provided below in Table 1. The completed backing material was stored for later use.
- the prepared backing material was then used to make a sample coated abrasive film as described herein.
- a make coat was applied to the backing material wherein the make coat was disposed onto the front coat of the backing material.
- Abrasive particles were disposed on the make coat and a size coat was applied over the make coat and abrasive particles. Details of the make coat, abrasive particles, and size coat are provided below in Table 2.
- the completed coated abrasive film was stored as a jumbo roll for later use.
- Example 2 Sample Lay Flat Abrasive Discs
- Sample coated abrasive film discs were prepared as described herein.
- Sample coated abrasive polishing film as prepared above in Example 1 was obtained from the jumbo roll and converted (i.e., cut) into a plurality of discs to make sample coated abrasive polishing discs.
- the discs did not exhibit any significant curling and laid flat compared to conventional coated abrasive polymer film discs (i.e., when the unused disc was resting on a flat surface, the height of the highest point of the disc was less than 10% of the diameter of the disc, such as even less than 5% of the diameter of the disc.
- the curvature of the sample abrasive disc embodiment 604 demonstrated that the sample disc was able to lay “flat” as described herein.
- the comparative conventional abrasive film disc 602 had an excessive curvature (excessive curl) and did not lay “flat.”
- the curvature of the sample abrasive disc embodiment 704 (backing side up) and a comparative conventional abrasive film disc 702 (backing side up) had an excessive curvature (excessive curl) and did not lay “flat.”
Abstract
Description
- This application claims priority under 35 U.S.C. § 119(e) to U.S. Patent Application No. 62/785,934, entitled “LAY FLAT COATED ABRASIVE DISCS,” by Paul S. GOLDSMITH and William C. RICE, filed Dec. 28, 2018, which is assigned to the current assignee hereof and incorporated herein by reference in its entirety.
- The present invention relates generally to coated abrasive articles that lay flat, such as coated abrasive discs, as well as methods of making and using said coated abrasive articles.
- Abrasive articles, such as coated abrasives, are used in various industries to machine work pieces, such as by lapping, grinding, and polishing. Surface processing using abrasive articles spans a wide industrial scope from initial coarse material removal to high precision finishing and polishing of surfaces at a submicron level.
- Effective and efficient abrasion of high performance metal, ceramic, and cermet industrial parts, such as drill bit components and aircraft engine parts, pose numerous processing challenges.
- Industries that produce such parts are sensitive to factors that influence operational costs, including the speed at which a surface can be prepared, the cost of the materials used to prepare that surface, and the costs associated with the time expended to prepare a surface.
- Therefore, there continues to be a demand for improved abrasive products and methods that can offer enhanced abrasive processing performance, efficiency, and improved surface quality.
- The present disclosure can be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.
-
FIG. 1 is an illustration of an embodiment of a coated abrasive article (a coated abrasive disc) that lays flat. -
FIG. 2 is an illustration of a cross sectional view of the coated abrasive article embodiment ofFIG. 1 and shows an abrasive layer disposed directly in contact with a layer of polymeric polyethylene composition. -
FIG. 3 is a flowchart of an embodiment of a method of making a coated abrasive article that lays flat. -
FIG. 4 is an illustration of an abrasive disc embodiment laying flat. -
FIG. 5 is an illustration of another abrasive disc embodiment laying flat. -
FIG. 6 is a photograph comparing the curvature of a sampleabrasive disc embodiment 604 and a conventionalabrasive disc 602 where the abrasive side of both abrasive discs faces upward. -
FIG. 7 is a photograph comparing the curvature of a sampleabrasive disc embodiment 704 and a conventionalabrasive disc 702 where the backing side of both abrasive discs faces upward. - The use of the same reference symbols in different drawings indicates similar or identical items.
- The following description, in combination with the figures, is provided to assist in understanding the teachings disclosed herein. The following discussion will focus on specific implementations and embodiments of the teachings. This discussion is provided to assist in describing the teachings and should not be interpreted as a limitation on the scope or applicability of the teachings.
- The term “averaged,” when referring to a value, is intended to mean an average, a geometric mean, or a median value. As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but can include other features not expressly listed or inherent to such process, method, article, or apparatus. As used herein, the phrase “consists essentially of” or “consisting essentially of” means that the subject that the phrase describes does not include any other components that substantially affect the property of the subject.
- Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
- The use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural, or vice versa, unless it is clear that it is meant otherwise.
- Further, references to values stated in ranges include each and every value within that range. When the terms “about” or “approximately” precede a numerical value, such as when describing a numerical range, it is intended that the exact numerical value is also included. For example, a numerical range beginning at “about 25” is intended to also include a range that begins at exactly 25. Moreover, it will be appreciated that references to values stated as “at least about,” “greater than,” “less than,” or “not greater than” can include a range of any minimum or maximum value noted therein.
- As used herein, the phrase “average particle diameter” can be reference to an average, mean, or median particle diameter, also commonly referred to in the art as D50.
- Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent not described herein, many details regarding specific materials and processing acts are conventional and can be found in textbooks and other sources within the coated abrasive arts.
-
FIG. 1 shows an illustration of a cross section of an embodiment of a coatedabrasive article 100. As shown inFIG. 1 , the coated abrasive article can include anabrasive layer 103 disposed on a backing material 101 (also called herein a “backing”). Thebacking material 101 can comprise abacking substrate 105 having a firstmajor surface 109 and a secondmajor surface 107, wherein a layer of a polymeric front coat composition 111 (also called herein a “front coat”) is disposed on the firstmajor surface 109 of the backing substrate, and wherein a layer of polymeric back coat composition 113 (also called herein a “back coat”) is disposed on the secondmajor surface 107 of the backing substrate. The abrasive layer can include a plurality ofabrasive particles 117 dispersed on or in a layer of polymeric binder composition 115 (also called herein a “make coat”). The layer ofpolymeric binder composition 115 can be disposed in direct contact with the polymericfront coat composition 111. A layer of polymeric size coat composition 119 (also called herein a “size coat”) can be disposed over thepolymeric binder composition 115 andabrasive particles 117. Further, an optional layer of polymeric supersize coat composition (not shown) can be disposed over thesize coat composition 119. In a particular embodiment, the coatedabrasive article 100 may further include a tool attachment layer (not shown) located opposite the abrasive layer and disposed in contact with the polymericback coat composition 113. -
FIG. 2 shows an illustration of a coatedabrasive article 200 embodiment. As shown inFIG. 2 , the coatedabrasive article 200 can include abody 201 that, in a particular embodiment, can be generally disc shaped.Abrasive particles 203 can be disposed on the working surface (also called herein the “abrasive surface” or “top surface”) of the abrasive article. In such an abrasive disc embodiment, the coatedabrasive article 200 can be configured to be removably engaged with a power sanding tool (not depicted) such as a random orbit sander or other type of powered disc sander. -
FIG. 3 is an illustration of a flowchart of an embodiment of amethod 300 of making a coated abrasive article having curl resistance and that lays flat.Step 302 includes disposing a layer of a polymeric front coat composition (also called herein a “front coat”) on a first major surface of a backing substrate.Step 304 includes disposing a layer of a polymeric back coat composition (also called herein a “back coat”) on a second major surface of the backing substrate. In an embodiment,step 302 andstep 304 can be accomplished at the same time. In another embodiment,step 302 andstep 304 can be accomplished separately.Step 306 includes disposing a layer of a polymeric make coat composition (also called herein a “make coat”) on the front coat.Step 308 includes disposing a plurality of abrasive particles on or in the make coat.Step 310 includes disposing a polymeric size coat composition (also called herein a “size coat”) over the abrasive particles and the make coat to form an abrasive article. The abrasive article can be used as a polishing film, a polishing belt, or converted (i.e., cut) into different shapes, such as discs, sheets, or other shapes.Step 312 includes cutting the abrasive article into a plurality of abrasive discs. Optionally, a tool attachment layer can be disposed on the back coat. -
FIG. 4 is an illustration of an abrasive disc embodiment laying flat. As used herein, the term “laying flat” means that when an abrasive disc is placed at rest on a flat surface that the disc has a curvature where the height (h) of the disc (i.e., the highest point of the disc) is less than or equal to 10% of the diameter of the disc. For instance, if a disc has a diameter (D) of 5 inches, the disc will be considered to lay flat if the height of the disc is equal to 0.5 inches or less. As shown inFIG. 4 , the curvature of the disc is such that the height of the center of the disc is elevated, but is less than 10% of the diameter of the disc. -
FIG. 5 is an illustration of another abrasive disc embodiment laying flat. As shown inFIG. 5 , the curvature of the disc is such that the highest point(s) (i.e., the height) of the disc is located at the elevated edge(s) of the disc, but is less than 10% of the diameter of the disc. -
FIG. 6 is a photograph showing an oblique downward view comparing the curvature of a sampleabrasive disc embodiment 604 and a conventionalabrasive disc 602. The abrasive surface of each abrasive disc faces upward away from the flat surface upon which the abrasive disc rests. The sampleabrasive disc 604 lays flat and has a curvature where the height of the disc is less than 10% of the diameter of the disc. The comparativeabrasive disc 602 does not lay flat. -
FIG. 7 is a photograph showing an oblique downward view comparing the curvature of a sampleabrasive disc embodiment 704 and a conventionalabrasive disc 702. The back surface (non abrasive surface) of each abrasive disc faces upward away from the flat surface upon which the abrasive disc rests. The sampleabrasive disc 704 lays flat and has a curvature where the height of the disc is less than 10% of the diameter of the disc. The comparativeabrasive disc 702 does not lay flat. - As previously stated, the backing material 101 (“backing”) comprises a
backing substrate 105 having a first major surface 109 (“first side”) and a second major surface 107 (“second side”), wherein a layer of a polymeric front coat composition 111 (also called herein a “front coat”) is disposed on the firstmajor surface 109 of the backing substrate, and wherein a layer of polymeric back coat composition 113 (also called herein a “back coat”) is disposed on the secondmajor surface 107 of the backing substrate. In an embodiment, thebacking material 101 can be beneficially flexible but also is resistant to curling and lays flat when at rest. Thebacking material 101 can comprise a proper combination of desired physical, chemical, mechanical, and/or performance properties and/or features to produce advantageous abrasive performance in combination with abrasive particles as described in greater detail herein. - The backing substrate can comprise a polymeric film, such as polyolefin film (e.g., polypropylene including biaxially oriented polypropylene), a polyester film (e.g., polyethylene terephthalate), a polyamide film, or a cellulose ester film; a metal foil; a mesh; a foam (e.g., natural sponge material or polyurethane foam); a cloth (e.g., cloth made from fibers or yarns comprising polyester, nylon, silk, cotton, poly-cotton, rayon, or combinations thereof); a paper; a vulcanized paper; a vulcanized rubber; a vulcanized fiber; a nonwoven material; a combination thereof. In an embodiment, the polymeric film can be a surface energy modified film, such as a primed film, a corona treated film, a plasma treated film, a chemically treated film, or a combination thereof. In a specific example, the backing substrate can comprise a polyester film that has been chemically primed and corona treated or plasma treated. Suitable chemical primers can include imide type primers, such as polyethylene imine, and the like.
- The backing substrate can have a surface energy in a beneficial range. In an embodiment, the surface energy of the film can be not less than 5 dyne, such as at least 10 dyne, at least 20 dyne, at least 30 dyne, at least 40 dyne, at least 45 dyne or at least 50 dyne. In an embodiment, the surface energy can be not greater than 100 dyne, such as not greater than 90 dyne, not greater than 80 dyne, not greater than 70 dyne, not greater than 65 dyne, or not greater than 60 dyne. The amount of surface energy can be within a range comprising any pair of the previous upper and lower limits. In an embodiment, the polymeric film can have an amount of surface energy not less than 5 dyne to not greater than 100 dyne, such as 20 dyne to 90 dyne, such as 30 dyne to 80 dyne, such as 40 dyne to 70 dyne, or 50 dyne to 60 dyne.
- The backing substrate can have a thickness in a beneficial range. In an embodiment, the thickness of the film can be not less than 1 mil, such as at least 2 mil, at least 2.5 mil, at least 3 mil, at least 3.5 mil, at least 4 mil, or at least 4.5 mil. In an embodiment, the thickness can be not greater than 9 mil, such as not greater than 8 mil, not greater than 7.5 mil, not greater than 7 mil, not greater than 6.5 mil, or not greater than 6 mil. The amount of thickness can be within a range comprising any pair of the previous upper and lower limits. In an embodiment, the polymeric film can have an amount of thickness not less than 1 mil to not greater than 9 mil, such as 2 mil to 8 mil, such as 2.5 mil to 7.5 mil, such as 3 mil to 7 mil, or 50 mil to 60 mil.
- In an embodiment, a layer of a polymeric front coat composition 111 (a “front coat”) is disposed on the first
major surface 109 of the backing substrate. In an embodiment, the polymeric front coat composition can comprise a polyethylene composition. The polyethylene composition can comprise a low density polyethylene (LDPE), a linear low-density polyethylene (LLDPE), a high-density polyethylene (HDPE), a medium-density polyethylene (MDPE), or an ultra-high-molecular-weight polyethylene (UHMWPE). In a specific embodiment, the polymeric front coat composition comprises a low density polyethylene. - In an embodiment, a layer of polymeric back coat composition 113 (a “back coat”) is disposed on the second
major surface 107 of the backing substrate. In an embodiment, the polymeric back coat composition can comprise an acrylate composition. The acrylate composition can comprise an ethyl acrylate, an ethylene acrylate, an ethylene-ethyl acrylate (EEA), a methyl acrylate, an ethylene methyl acrylate (EMA) copolymer, a butyl acrylate, a copolymer of ethylene and butyl acrylate (EBA), an ethylene acrylic ester terpolymer (i.e., a terpolymer of ethylene, acrylic ester, and maleic anhydride), or a combination thereof. In a specific embodiment, the back coat composition comprises a mixture of 1) a copolymer of ethylene and butyl acrylate (EBA), and 2) an ethylene acrylic ester terpolymer (i.e., a terpolymer of ethylene, acrylic ester, and maleic anhydride). - In an embodiment, the abrasive layer can include a plurality of
abrasive particles 117 dispersed on or in a layer of polymeric binder 115 (“make coat”). In an embodiment, the abrasive particles can be blended together with the polymeric binder to form an abrasive slurry wherein the abrasive particles are dispersed throughout the binder formulation. Alternatively, the polymeric binder composition can be coated onto the backing material and the abrasive particles then applied over the binder composition. Optionally, patterns can be formed in the abrasive layer by molding, pressing, or tooling of the abrasive layer. - Abrasive particles can include alumina, silicon carbide, silica, ceria, and harder, high performance superabrasive particles such as cubic boron nitride and diamond. The abrasive particles can be essentially single phase inorganic materials, mixed phase materials, or combinations thereof. Additionally, the abrasive particles can include composite particulate materials, such as aggregates, which can be formed through slurry processing pathways that include removal of the liquid carrier through volatilization or evaporation, leaving behind unfired (“green”) aggregates, that can optionally undergo high temperature treatment (i.e., firing, sintering) to form usable, fired aggregates. Further, the abrasive layer can include engineered abrasives including macrostructures and particular three-dimensional structures.
- The abrasive particles can be formed of any one of or a combination of abrasive particles, including silica, alumina (ceramic, fused, or sintered), zirconia, zirconia/alumina oxides, silicon carbide, garnet, diamond, cubic boron nitride, silicon nitride, ceria, titanium dioxide, titanium diboride, boron carbide, tin oxide, tungsten carbide, titanium carbide, iron oxide, chromia, flint, emery. For example, the abrasive particles can be selected from a group consisting of silica, alumina, zirconia, silicon carbide, silicon nitride, boron nitride, garnet, diamond, co-fused alumina zirconia, ceria, titanium diboride, boron carbide, flint, emery, alumina nitride, and a blend thereof. Particular embodiments have been created by use of abrasive particles comprised of diamond.
- In an embodiment, the abrasive particles can be diamond particles (also referred to herein as “diamonds”), cubic boron nitride particles, or combinations thereof. In an embodiment, the abrasive particles comprise diamonds. The diamonds can be monocrystalline, polycrystalline, or a combination thereof. The diamonds can be natural diamonds, synthetic diamonds, metal coated diamonds, resin coated diamonds, or combinations thereof. The abrasive particles can be loose diamonds, diamond agglomerates, diamond aggregates, or a combination thereof.
- In specific embodiments, superabrasive particles include cubic boron nitride and diamond particles. These superabrasive particles can be natural (e.g. natural diamond) or synthetic (e.g. cubic boron nitride and synthetic diamond) products. The superabrasive particles may have a blocky shape associated with them or alternatively, a needle-like shape. The superabrasive particles may be surface coated or not surface coated. In an embodiment, a blend of superabrasive particles and conventional abrasive particles (e.g. alumina, silicon carbide, ceria, and silica) can be used.
- The abrasive particles can have a particular shape, such as a rod, a triangle, a pyramid, a cone, a solid sphere, a hollow sphere, or the like. Alternatively, the abrasive particles can be randomly shaped.
- The abrasive particles can be in a beneficial size range, conform to a beneficial size distribution, or a combination thereof. In an embodiment, the abrasive particles can have an average particle size of not less than 1 micron, such as at least 2 micron, at least 3 micron, at least 5 micron, at least 10 micron, at least 15 micron, at least 20 micron, or at least 25 micron. In an embodiment, the average particle size can be not greater than 500 micron, such as not greater than 400 micron, not greater than 300 micron, not greater than 200 micron, not greater than 150 micron, or not greater than 125 micron. The average particle size can be within a range comprising any pair of the previous upper and lower limits. In an embodiment, the abrasive particles can have an average particle size not less than 5 micron to not greater than 250 micron, such as 10 micron to 200 micron, such as 15 micron to 150 micron, such as 20 micron to 125 micron.
- As stated previously, a layer of
polymeric binder composition 115 can be disposed in direct contact with the polymericfront coat composition 111. In a particular aspect, thepolymeric binder composition 115 can be comprised of a single polymer or a blend of polymers. - The binder composition can be formed from an epoxy composition, an acrylic composition, a phenolic composition, a polyurethane composition, a urea formaldehyde composition, a polysiloxane composition, or combinations thereof. In addition, the binder composition can include active filler particles, additives, or a combination thereof, as described herein.
- The binder composition generally includes a polymer matrix, which binds abrasive particles to the backing or to a compliant coat, if such a compliant coat is present. Typically, the binder composition is formed of cured binder composition. In an embodiment, the binder composition includes a polymer component and a dispersed phase.
- The binder composition can include one or more reaction constituents or polymer constituents for the preparation of a polymer. A polymer constituent can include a monomeric molecule, a polymeric molecule, or a combination thereof. The binder composition can further comprise components selected from the group consisting of solvents, plasticizers, chain transfer agents, catalysts, stabilizers, dispersants, curing agents, reaction mediators and agents for influencing the fluidity of the dispersion.
- The polymer constituents can form thermoplastics or thermosets. By way of example, the polymer constituents can include monomers and resins for the formation of polyurethane, polyurea, polymerized epoxy, polyester, polyimide, polysiloxanes (silicones), polymerized alkyd, styrene-butadiene rubber, acrylonitrile-butadiene rubber, polybutadiene, or, in general, reactive resins for the production of thermoset polymers. Another example includes an acrylate or a methacrylate polymer constituent. The precursor polymer constituents are typically curable organic material (i.e., a polymer monomer or material capable of polymerizing or crosslinking upon exposure to heat or other sources of energy, such as electron beam, ultraviolet light, visible light, etc., or with time upon the addition of a chemical catalyst, moisture, or other agent which cause the polymer to cure or polymerize). A precursor polymer constituent example includes a reactive constituent for the formation of an amino polymer or an aminoplast polymer, such as alkylated urea-formaldehyde polymer, melamine-formaldehyde polymer, and alkylated benzoguanamine-formaldehyde polymer; acrylate polymer including acrylate and methacrylate polymer, alkyl acrylate, acrylated epoxy, acrylated urethane, acrylated polyester, acrylated polyether, vinyl ether, acrylated oil, or acrylated silicone; alkyd polymer such as urethane alkyd polymer; polyester polymer; reactive urethane polymer; phenolic polymer such as resole and novolac polymer; phenolic/latex polymer; epoxy polymer such as bisphenol epoxy polymer; isocyanate; isocyanurate; polysiloxane polymer including alkylalkoxysilane polymer; or reactive vinyl polymer. The binder composition can include a monomer, an oligomer, a polymer, or a combination thereof. In a particular embodiment, the binder composition includes monomers of at least two types of polymers that when cured can crosslink.
- In an embodiment, the binder composition can include epoxy constituents and acrylic constituents that when cured form an epoxy/acrylic hybrid polymer. Alternatively, the binder composition can comprise a butyl acrylate polymer. In an embodiment, the binder composition can comprise a cycloaliphatic epoxy resin, a di-acrylate resin, or a combination thereof. In a specific embodiment, the binder composition can comprise a hydrogenated diphenylolpropane (DPP) epoxy resin, an oxetane resin (4-member cyclic ether), a bisphenol A Epoxy Diacrylate resin (diacrylate ester of a bisphenol A epoxy resin), a propoxylated neopentyl glycol diacrylate resin, or combinations thereof.
- As described above, layer of polymeric size coat composition 119 (a “size coat”) can be disposed over the
polymeric binder composition 115 andabrasive particles 117. Thesize coat composition 119 can be the same as or different from thepolymeric binder composition 115 of the abrasive layer 103 (i.e., the size coat composition can be the same as or different than the make coat composition). The size coat composition can include one or more fillers, additives, or a combination thereof. - In a specific embodiment, the
size coat composition 119 can comprise an epoxy resin, an acrylic resin, an acrylate resin, an epoxy acrylate resin, or a combination thereof. In an embodiment, the size coat composition can comprise a reinforcing additive, such as amorphous silica. In a specific embodiment, the size coat composition can comprise a cycloaliphatic epoxy resin, an epoxide, a diepoxide, a butanediol, a triacrylate, a hexaacrylate, a cyclohexylcarboxylate, or a combination thereof. In a specific embodiment, the size coat composition can comprise a silica reinforced cycloaliphatic epoxy resin, an aliphatic epoxidized butanediol, trimethylolpropane triacrylate (TMPTA), dipentaerythritol hexaacrylate (DPHA), (3,4-epoxycyclohexane) methyl 3,4-epoxycyclohexylcarboxylate, or a combination thereof. - In a specific embodiment, the size coat composition can include 5 wt % to 45 wt % of a reinforcing filler, such 10 wt % to 35 wt % of a reinforcing filler.
- As previously described, the coated
abrasive article 100 can optionally comprise a layer of supersize coat composition (not shown) disposed on thesize coat composition 119. The supersize coat composition can be the same as or different from thepolymeric binder composition 115 of theabrasive layer 103 and can be same as or different than thesize coat composition 119 disposed thereon. In another aspect, the supersize coat composition may comprise an anti-loading agent (such as a stearate, such as a metal stearate, such as zinc stearate or calcium stearate) or a grinding aid (such as cryolite, potassium borofluorate), or a combination thereof. - In a particular aspect, the
front coat composition 111, theback coat composition 113, thebinder composition 115, thesize coat composition 119, or the supersize coat composition (not shown) can include one or more additives. Additives can be available in an amount of 0 wt % to 10 wt % of any polymer layer (i.e., make coat layer, size coat layer, or supersize layer). Suitable additives, for example, can include grinding aids, fibers, lubricants, wetting agents, thixotropic materials, surfactants, thickening agents, pigments, dyes, antistatic agents, coupling agents, plasticizers, suspending agents, pH modifiers, adhesion promoters, lubricants, bactericides, fungicides, flame retardants, degassing agents, anti-dusting agents, dual function materials, initiators, chain transfer agents, stabilizers, dispersants, reaction mediators, colorants, and defoamers. The amounts of these additive materials can be selected to provide the properties desired. These optional additives can be present in any part of the overall system of the coated abrasive product according to embodiments of the present disclosure. Suitable grinding aids can be inorganic based; such as halide salts, for example cryolite, wollastonite, and potassium fluoroborate; or organic based, such as sodium lauryl sulphate, or chlorinated waxes, such as polyvinyl chloride. In an embodiment, the grinding aid can be an environmentally sustainable material. - The abrasive article can optionally include a tool attachment layer. In a particular embodiment, the coated
abrasive article 100 includes a tool attachment layer (not shown) that can be used to removably engage the coatedabrasive article 100 with a power tool, such as a rotary sander. The tool attachment layer can include an adhesive. - In another aspect, the tool attachment layer can include a mechanical fastener. For example, the mechanical fastener can include a hook fastener, a loop fastener, or a combination thereof that is configured to removably engage with a corresponding mechanical fastener on the tool on which the coated
abrasive article 100 is intended to be disposed during abrasive operations. - Embodiment 1. A coated abrasive article comprising: an abrasive layer disposed on a backing material; wherein the backing material comprises: a backing substrate having a first side and a second side, and a layer of polymeric polyethylene composition disposed on the first side of the backing substrate; wherein the abrasive layer is disposed directly in contact with the polymeric polyethylene composition.
- Embodiment 2. The coated abrasive article of embodiment 1, wherein the coated abrasive article lays flat.
- Embodiment 3. The coated abrasive article of embodiment 1, wherein the coated abrasive article has a curvature of not greater than 10% of the diameter of the abrasive article.
- Embodiment 4. The coated abrasive article of embodiment 1, wherein the abrasive layer comprises a make coat or a size coat having a Young's modulus (stiffness) of at least 150 kpsi, such as at least 200 kpsi, at least 250 kpsi, at least 300 kpsi, at least 350 kpsi, at least 400 kpsi, at least 450 kpsi, or at least 500 kpsi.
- Embodiment 5. The coated abrasive article of embodiment 4, wherein the abrasive layer comprises a make coat or a size coat having a Young's modulus (stiffness) of not greater than 900 kpsi, such as not greater than 850 kpsi, not greater than 800 kpsi, not greater than 750 kpsi, not greater than 700 kpsi, not greater than 650 kpsi, or not greater than 600 kpsi.
- Embodiment 6. The coated abrasive article of embodiment 1, wherein the polymeric polyethylene composition comprises low density polyethylene, high density polyethylene, or a combination thereof.
- Embodiment 7. The coated abrasive article of embodiment 1, wherein the layer of polymeric polyethylene composition comprises a thickness of at least 0.25 mil to not greater than 0.5 mil, such as at least 1 mil to not greater than 3 mil, or at least 1.5 mil to not greater than 2.5 mil.
- Embodiment 8. The coated abrasive article of embodiment 1, further comprising a layer of polymeric acrylate composition disposed on a second side of the backing substrate.
- Embodiment 9. The coated abrasive article of embodiment 8, wherein the polymeric acrylate composition comprises ethyl acrylate, ethylene acrylate, ethylene-methyl acrylate, ethylene-ethyl acrylate, or a combination thereof.
- Embodiment 10. The coated abrasive article of embodiment 8, wherein the layer of polymeric acrylate composition comprises a thickness of at least 0.1 mil to not greater than 3 mil, such as at least 0.25 mil to not greater than 2.5 mil, or at least 0.5 mil to not greater than 2 mil.
- Embodiment 11. The coated abrasive article of embodiment 1, wherein the backing substrate comprises a polymeric film.
- Embodiment 12. The coated abrasive article of embodiment 11, wherein the polymeric film comprises a polyester film.
- Embodiment 13. The coated abrasive article of embodiment 11, wherein the polymeric film comprises polyethylene terephthalate.
- Embodiment 14. The coated abrasive article of embodiment 11, wherein the polymeric film comprises a thickness of at least 1 mil to not greater than 10 mil, such as at least 2 mil to not greater than 8 mil, at least 3 mil to not greater than 7 mil, or at least 4 mil to not greater than 6 mil.
- Embodiment 15. The coated abrasive article of embodiment 11, wherein the polymeric film comprises a surface energy of at least 40 dyne/cm2, such as at least 45 dyne/cm2.
- Embodiment 16. The coated abrasive article of embodiment 15, wherein the polymeric film is corona treated.
- Embodiment 17. The coated abrasive article of embodiment 1, wherein the abrasive layer comprises a polymeric make coat composition and abrasive particles disposed in the make coat composition.
- Embodiment 18. The coated abrasive article of embodiment 17, wherein the make coat composition comprises an epoxy acrylate polymer, an epoxy methacrylate polymer, a butyl acrylate polymer, or a combination thereof.
- Embodiment 19. The coated abrasive article of embodiment 17, wherein the make coat composition further comprises a filler.
- Embodiment 20. The coated abrasive article of embodiment 17, wherein the abrasive layer further comprises a polymeric size coat composition disposed on the make coat composition and abrasive particles.
- Embodiment 21. The coated abrasive article of embodiment 17, wherein the size coat composition comprises an epoxy acrylate polymer, an epoxy methacrylate polymer, a butyl acrylate polymer, or a combination thereof.
- Embodiment 22. The coated abrasive article of embodiment 17, wherein the make coat composition further comprises a filler.
- Embodiment 23. The coated abrasive article of embodiment 17, wherein the abrasive particles comprise diamond, cubic boron nitride, or a combination thereof.
- Embodiment 24. The coated abrasive article of embodiment 23, wherein the abrasive particles comprise a grit size of 5 microns to 500 microns.
- Sample coated abrasive film was prepared as described herein. In a first step, a backing material was prepared by applying a front coat and a back coat to a backing substrate. Details of the backing material are provided below in Table 1. The completed backing material was stored for later use.
-
TABLE 1 Backing Material S1 Front Coat Low density polyethylene Backing Polymer film1, primed2, and corona treated3 Substrate Back Coat Copolymer Blend 90-95 wt % ethylene and butyl acrylate copolymer 05-10 wt % ethylene acrylic ester terpolymer5 1Chemically treated PET film, 5 mil thick 2Primer—polyethylene imine 350-60 dyne/cm2, both sides 4Lotryl, Arkema, Inc. 5Lotader, Arkema, Inc. - The prepared backing material was then used to make a sample coated abrasive film as described herein. A make coat was applied to the backing material wherein the make coat was disposed onto the front coat of the backing material. Abrasive particles were disposed on the make coat and a size coat was applied over the make coat and abrasive particles. Details of the make coat, abrasive particles, and size coat are provided below in Table 2. The completed coated abrasive film was stored as a jumbo roll for later use.
-
TABLE 2 Coated Abrasive Film S1 Size Coat UV curable copolymer blend 40-65 wt % epoxy resin 39 10-20 wt % epoxy resin 410 1-10 wt % acrylate resin 211 0-5 wt % acrylate resin 312 0-5 wt % epoxy acrylate resin13 10-20 wt % filler14 Abrasive Metal bond diamond, 65-75 micron Particles Make Coat UV curable copolymer blend 55-75 wt % epoxy resin 16 05-12 wt % epoxy resin 27 10-20 wt % oxetane 1-08 wt % acrylate resin8 6Diphenylolpropane (DPP) resin—Eponex 7Bisphenol A Epoxy Diacrylate—Ebecryl 8Propoxylated neopentyl glycol diacrylate—Sartomer 9Silica reinforced cycloaliphatic epoxy resin (Nanopox) 10Aliphatic epoxidized butanediol (Erisyg) 11Trimethylolpropane triacrylate (TMTPA) 12Dipentaerythritol hexaacrylate (DPHA) 13methyl 3,4-epoxycyclohexylcarboxylate 14Amorphous silica - Sample coated abrasive film discs were prepared as described herein. Sample coated abrasive polishing film as prepared above in Example 1 was obtained from the jumbo roll and converted (i.e., cut) into a plurality of discs to make sample coated abrasive polishing discs. Surprisingly, even thought the discs were obtained from material near the center of the jumbo roll, the discs did not exhibit any significant curling and laid flat compared to conventional coated abrasive polymer film discs (i.e., when the unused disc was resting on a flat surface, the height of the highest point of the disc was less than 10% of the diameter of the disc, such as even less than 5% of the diameter of the disc. As shown in
FIG. 6 , the curvature of the sample abrasive disc embodiment 604 (abrasive face up) demonstrated that the sample disc was able to lay “flat” as described herein. In contrast, the comparative conventional abrasive film disc 602 (abrasive face up) had an excessive curvature (excessive curl) and did not lay “flat.” Similarly, as shown inFIG. 7 , the curvature of the sample abrasive disc embodiment 704 (backing side up) and a comparative conventional abrasive film disc 702 (backing side up) had an excessive curvature (excessive curl) and did not lay “flat.” - In the foregoing, reference to specific embodiments and the connections of certain components is illustrative. It will be appreciated that reference to components as being coupled or connected is intended to disclose either direct connection between said components or indirect connection through one or more intervening components as will be appreciated to carry out the methods as discussed herein. As such, the above-disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, which fall within the true scope of the present invention. Moreover, not all of the activities described above in the general description or the examples are required, that a portion of a specific activity cannot be required, and that one or more further activities can be performed in addition to those described. Still further, the order in which activities are listed is not necessarily the order in which they are performed.
- The disclosure is submitted with the understanding that it will not be used to limit the scope or meaning of the claims. In addition, in the foregoing disclosure, certain features that are, for clarity, described herein in the context of separate embodiments, can also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, can also be provided separately or in any subcombination. Still, inventive subject matter can be directed to less than all features of any of the disclosed embodiments.
- Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that can cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.
- Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description.
Claims (20)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US16/714,215 US20200206874A1 (en) | 2018-12-28 | 2019-12-13 | Lay flat coated abrasive discs |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201862785934P | 2018-12-28 | 2018-12-28 | |
US16/714,215 US20200206874A1 (en) | 2018-12-28 | 2019-12-13 | Lay flat coated abrasive discs |
Publications (1)
Publication Number | Publication Date |
---|---|
US20200206874A1 true US20200206874A1 (en) | 2020-07-02 |
Family
ID=71123677
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/714,215 Pending US20200206874A1 (en) | 2018-12-28 | 2019-12-13 | Lay flat coated abrasive discs |
Country Status (1)
Country | Link |
---|---|
US (1) | US20200206874A1 (en) |
Citations (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2431258A (en) * | 1946-02-05 | 1947-11-18 | Carborundum Co | Coated abrasive article and method of manufacturing the same |
US5700302A (en) * | 1996-03-15 | 1997-12-23 | Minnesota Mining And Manufacturing Company | Radiation curable abrasive article with tie coat and method |
US20090035519A1 (en) * | 2007-08-03 | 2009-02-05 | Saint-Gobain Abrasives, Inc. | Abrasive article with anti-slip polymeric layer |
US7540801B2 (en) * | 2006-02-23 | 2009-06-02 | Oy Kwh Mirka Ab | Oscillating grinding machine |
US20120055096A1 (en) * | 2010-05-28 | 2012-03-08 | Saint-Gobain Abrasifs | Non-abrasive back coat for coated abrasives |
US8287611B2 (en) * | 2005-01-28 | 2012-10-16 | Saint-Gobain Abrasives, Inc. | Abrasive articles and methods for making same |
WO2014131936A1 (en) * | 2013-02-26 | 2014-09-04 | Kwh Mirka Ltd | A method to provide an abrasive product surface and abrasive products thereof |
WO2015168229A1 (en) * | 2014-05-01 | 2015-11-05 | 3M Innovative Properties Company | Coated abrasive article |
US20160144477A1 (en) * | 2014-11-21 | 2016-05-26 | Diane Scott | Coated compressive subpad for chemical mechanical polishing |
US10195713B2 (en) * | 2016-08-11 | 2019-02-05 | 3M Innovative Properties Company | Lapping pads and systems and methods of making and using the same |
US11040429B2 (en) * | 2015-09-08 | 2021-06-22 | 3M Innovative Properties Company | Abrasive rotary tool with abrasive agglomerates |
US11529764B2 (en) * | 2018-12-31 | 2022-12-20 | Saint-Gobain Abrasives, Inc. | Coated abrasive film belt |
-
2019
- 2019-12-13 US US16/714,215 patent/US20200206874A1/en active Pending
Patent Citations (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2431258A (en) * | 1946-02-05 | 1947-11-18 | Carborundum Co | Coated abrasive article and method of manufacturing the same |
US5700302A (en) * | 1996-03-15 | 1997-12-23 | Minnesota Mining And Manufacturing Company | Radiation curable abrasive article with tie coat and method |
US8287611B2 (en) * | 2005-01-28 | 2012-10-16 | Saint-Gobain Abrasives, Inc. | Abrasive articles and methods for making same |
US7540801B2 (en) * | 2006-02-23 | 2009-06-02 | Oy Kwh Mirka Ab | Oscillating grinding machine |
US20090035519A1 (en) * | 2007-08-03 | 2009-02-05 | Saint-Gobain Abrasives, Inc. | Abrasive article with anti-slip polymeric layer |
US20120055096A1 (en) * | 2010-05-28 | 2012-03-08 | Saint-Gobain Abrasifs | Non-abrasive back coat for coated abrasives |
WO2014131936A1 (en) * | 2013-02-26 | 2014-09-04 | Kwh Mirka Ltd | A method to provide an abrasive product surface and abrasive products thereof |
WO2015168229A1 (en) * | 2014-05-01 | 2015-11-05 | 3M Innovative Properties Company | Coated abrasive article |
US20160144477A1 (en) * | 2014-11-21 | 2016-05-26 | Diane Scott | Coated compressive subpad for chemical mechanical polishing |
US11040429B2 (en) * | 2015-09-08 | 2021-06-22 | 3M Innovative Properties Company | Abrasive rotary tool with abrasive agglomerates |
US10195713B2 (en) * | 2016-08-11 | 2019-02-05 | 3M Innovative Properties Company | Lapping pads and systems and methods of making and using the same |
US11529764B2 (en) * | 2018-12-31 | 2022-12-20 | Saint-Gobain Abrasives, Inc. | Coated abrasive film belt |
Non-Patent Citations (1)
Title |
---|
https://web.archive.org/web/20181111151029/https://en.wikipedia.org/wiki/Polyethylene_glycol, 2018-NOV-11 (Year: 2018) * |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US20230098736A1 (en) | Coated abrasive film belt | |
US10556322B2 (en) | Abrasive flap disc including wearable backing plate | |
US20220161392A1 (en) | Abrasive articles including a blend of abrasive particles and method of forming and using the same | |
US20220001513A1 (en) | Coated abrasives having aggregates | |
US9221151B2 (en) | Abrasive articles including a blend of abrasive grains and method of forming same | |
US11945076B2 (en) | Articles including polyester backing and primer layer and related methods | |
US9931731B2 (en) | Compressed polymer impregnated backing material abrasive articles incorporating same, and processes of making and using | |
US20200206874A1 (en) | Lay flat coated abrasive discs | |
US20210197341A1 (en) | Coated abrasive with enhanced supersize composition | |
US20180369989A1 (en) | Coated abrasives having a supersize layer including an active filler | |
US11660726B2 (en) | Coated abrasives having an improved supersize coating | |
US20210197342A1 (en) | Rigid backsize to prevent fiber disc curling |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: SAINT-GOBAIN ABRASIVES, INC., MASSACHUSETTS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:GOLDSMITH, PAUL S.;RICE, WILLIAM C.;REEL/FRAME:051922/0556 Effective date: 20200102 Owner name: SAINT-GOBAIN ABRASIFS, FRANCE Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:GOLDSMITH, PAUL S.;RICE, WILLIAM C.;REEL/FRAME:051922/0556 Effective date: 20200102 |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: APPLICATION DISPATCHED FROM PREEXAM, NOT YET DOCKETED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: FINAL REJECTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE AFTER FINAL ACTION FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: ADVISORY ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |