US3402034A - Coated abrasive products - Google Patents
Coated abrasive products Download PDFInfo
- Publication number
- US3402034A US3402034A US497644A US49764465A US3402034A US 3402034 A US3402034 A US 3402034A US 497644 A US497644 A US 497644A US 49764465 A US49764465 A US 49764465A US 3402034 A US3402034 A US 3402034A
- Authority
- US
- United States
- Prior art keywords
- backing
- coated abrasive
- sheet
- abrasive
- spun bonded
- 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.)
- Expired - Lifetime
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D11/00—Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
- B24D11/02—Backings, e.g. foils, webs, mesh fabrics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/30—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being formed of particles, e.g. chips, granules, powder
Definitions
- This invention relates to coated abrasive products and more particularly to coated abrasive products which are eminently useful in the wet sanding of various articles; such products being in the form of sheets, discs and belts.
- a primary object of the present invention is to provide a coated abrasive article which overcomes the abovedescribed disadvantages and which provides a flexible structure which maintains its aggressive cutting value under wet and other adverse conditions; in addition an article which resists heat build-up during dry sanding or finishing operations.
- a further object is to provide a plasticbacked abrasive article which is non-warping or non- 3,402,034 Patented Sept. 17, 1968 curling and which may be effectively held during hand sanding operations while at the same time maintaining its aggressive cutting value.
- Still another object is to provide an abrasive article having a flexible plastic-backing which is provided with a flexible coating for retaining its abrasive action.
- FIG. 1 is an enlarged view of the backing for the coated abrasive articles of this invention
- FIG. 2 is a greatly enlarged sectional view showing the fibers of the backing of the coated abrasive articles of this invention and taken on the line 22 of FIG. 1;
- FIG. 3 is a greatly enlarged sectional view showing the fibers of the backing of the coated abrasive articles of this invention surrounded by a vinyl chloride polymer;
- FIG. 4 is a perspective view of a coated abrasive article embodying my invention.
- a coated abrasive article which is highly resistant to moisture and heat build-up, whichis flexible and in the form of a sheet, disc or belt may be made by using a backing for the coated abrasive product composed of a sheet of self-bonded linear polyethylene fibers, which sheet material has been saturated or impregnated with vinyl chloride polymers and copolymers or a modified epoxy resin.
- the sheet materials which are formed of linear polyethylene fibers are paper-like in hand and appearance. Such materials are commercially available from E. I. du Pont de Nemours & Company and have been described as spun bonded which is a descriptive term for fiber structures manufactured from continuous synthetic polymeric filamentary materials in an integrated spinning and bonding process.
- the spun bonded sheet is formed by the random distribtuion of many minute continuous fibers (ordinarily less than about 4 microns in thickness) in web form.
- the fibers are selfbonded with no binder being employed to maintain sheet integrity.
- the problems associated with the use of a spun bonded polyethylene sheet material in coated abrasives may be substantially reduced and even eleminated by impregnating the spun bonded sheet material with colloidal dispersions of vinyl chloride polymers and copolymers or a modified epoxy resin.
- compositions not only gives vastly improved adhesion of the maker coat to the backing, but also improves the internal adhesion of the spun bonded sheet material as well as increases the flexibility of the backing and reduces the tinniness associated with such materials.
- the impregnated backing has reduced stretch over the non-impregnated material which makes the completed coated abrasive product much more suitable for use in coated abrasive belts.
- epoxy resins utilized in this invention are not considered as the hard or rigid type, but can be described as just as soft or even softer than the usual soft vulcanized rubber elastomers. These chemically modified epoxy resins can be further described as a combination of an epoxy resin, polyester and polyamide.
- the epoxy resins employed in the present invent-ion are the reaction product of epichlorohydrin with a dihydric phenol. Because of its ready availability, bisphenol A[bis (4-hydroxyphenyl)dimethylmethane] is preferred. The reaction is carried out in the presence of a caustic such as sodium hydroxide with the epichlorohydrin being employed in excess.
- the epoxy resins suitable for use in this invention may be characterized as having an epoxide equivalent of from 170 to 200; a viscosity at 25 C. in
- centipoises of from 3000 to 20,000; an average molecular weight of about twice the epoxide equivalent and are usually in a liquid condition at room temperature.
- the polyamide component of the resin can be characterized as the condensation polymer of dim'erized (and trimerized) vegetable oils, unsaturated fatty acids, and aryl or alkyl polyamines.
- the polyamides are amber colored thermoplastic resins with molecular weights ranging from about 3000 to about 10,000 and melting points ranging up to about 190 C.
- the polyamides having lower molecular weights, up to about 6,000, and lower melting points are used in this binder. I also prefer to use the polyamides in which a higher amine such as DETA is used in preference to ethylenediamine.
- polyamides having higher amine values such as those having amine values ranging from about 290450, with those polyamides having amine values ranging from 350-400 giving excellent results.
- the polyamides used can be further identified as having a viscosity (Gardner-Holdt) of from about ZOO-1,000 cps. at 25 C. Versamid 140 (available from General Mills) and D.E.H. 14 (available from Dow Chemical Co.) are two examples of polyamides which perform exceptionally well in the impregnating composition.
- the polyamide component serves to cure the epoxy resin and to fiexibilize the resin.
- the weight ratio of polyamide to epoxy resin in the saturant is ordinarily from about 0.5/1 to about 1/1.
- the polyesters useful in the resin composition are the long chain polyesters having chain lengths of at least 14 members.
- the chains may be terminated either with carboxy or alcoholic hydroxyl group depending on the ratio of reactants employed in the synthesis.
- Excellent results have been obtained with a polyester identified as PL-S available from General Resin Corporation and comprising the reaction product of approximately 3 mols of phthalic acid, 7 mols of adipic acid and 12 mols of dipropylene glycol.
- the weight ratio of polyester to epoxy resin is about 0.25/1 to about 1/1.
- the epoxy resin, polyamide and polyester are mixed together and thinned with a suitable solvent for ease in applying the binder to the fibrous web.
- the solvent is volatile; methylene chloride has proved to be an excellent solvent for this purpose.
- the vinyl chloride polymers and copolymers useful in this invention may be described as colloidal dispersions in water having from about 48-58% total solids.
- preplasticized or internally plasticized latices such as are commercially available under the trademark Geon (BF. Goodrich Checimal Company).
- An example of a suitable material is Geon 576 which is a preplasticized vinyl latex consisting of about 100 parts of resin solids with 35 parts of dioctyl phthalate.
- Geon 652 is a further example of a latex suitable for use as a saturant. It is an internally plasticized latice being a copolymer of vinyl chloride and vinylidene chloride.
- Dioctyl phthalate, dioctyl adipate and tricresyl phosphate are preferred since they ordinarily produce flexible films.
- Plasticizers such as propylene glycol and carbitol acetate are not desirable as plasticizers since the resulting films are too hard.
- impregnation of the spun bonded backing may be accomplished in a number of ways, I prefer to use the so-called dip-squeeze method whereby the spun bonded backing is passed through a tank containing the saturant and thereafter passed through rubber squeeze rolls to remove the excess saturant and give the desired ratio of saturant to backing.
- the maker coat for imbedding the abrasive grains and uniting the grain to the impregnated spun bonded polyethylene sheet may consist of a urethane elastomer with such urethane elastomer ordinarily including the nonfoaming group of polyol isocyanate products in solid or liquid phase which are usually made from diisocyamates and linear polyesters such as ethylene glycol adipate.
- a top-sizing such as an epoxy novolac resin.
- the epoxy novolac resin is fully compatible with the more flexible urethane elastomer maker coating and this combination results in a very firm anchoring of the abrasive, at the same time providing an upper hard-wear surface which is highly resistant to heat.
- An epoxy novolac resin having at least 3 reaction epoxy groups is found to be highly effective. Such a material is produced by reacting epichlorohydrin with phenol formaldehyde to produce an epoxy resin product having 3 or more reaction groups. Such a product is on the market as epoxy novolac resin (DOW D.E.N. 438-A).
- a coated abrasive sheet comprising a layer of abrasive grains 12, the grains being firmly united to an impregnated spun bonded ethylene backing sheet 15 by means of maker coat 16.
- a top-sizing 17 is applied over the maker coat 16 which provides an upper wear surface highly resistant to heat.
- a very fine abrasive filler such as diatomaceous earth can be mixed in to the resin for impregnating the spun bonded polyethylene sheet and the addition of such an abrasive filler will provide a non-skid surface on the underside 18 of the backing 15.
- FIGS. 1, 2 and 3 depict the spun bonded backing material of the coated abrasive product of this invention in greater detail;
- FIG. 1 is a greatly enlarged view of a portion of a piece of non-impregnated spun bonded polyethylene sheet material showing the random distribution of many minute continuous fibers 20 in web form. These fibers are self-bonded and no binder is employed to maintain the integrity of the sheet.
- FIG. 2 is a greatly enlarged and partsectional view of fibers from the sheet material shown in FIG. 1.
- FIG. 3 there is depicted the fibers as shown in FIG. 2 with the addition of the impregnating resin or saturant 21 fully surrounding and filling the interstices between fibers 20.
- the abrasive grains may be deposited in any manner. If desired, they may be mixed in a slurry with the maker adhesive and the slurry deposited upon the sheet backing 15, or the grains may be deposited upon the maker coating after the maker has been applied to the backing sheet 15.
- the abrasive materials utilized may include all of the suitable or well known abrasives such as silicon carbide, aluminum oxide, garnet, flint, emery and pumice in varying grit size.
- DEH-14 (a polyamide curing agent and flexibilizer having an amine value of 350-400; a viscosity of 200-600 cps. at 75 C. [Gardner-Holdt] and available from Dow Chemical Company).
- An epoxy novolac resin having an average of 3.6 epoxy groups per molecule can be represented by the structure This resin reacts through its epoxy groups with all known curing agents and catalysts.
- This resin has an epoxide equivalent weight of 175-182; a viscosity at 25 C. (cps.) of 500- 1200; specific gravity, 25/4" C. of 1.12-1.12; with a weight of about 9.5 pounds/ gallon.
- the spun bonded polyethylene sheet material was previously impregnated with a vinyl chloride-vinylidene chloride copolymer having the following formulation:
- Geon 652 (a copolymer of vinyl chloride and vinylidene chloride, internally plasticized and having a solids content of 49-52%; pH at 6.0; viscosity [Brookfield at R. T.] of 7-12 cps.; a specific gravity of 1.120-1.132) parts Acrysol A-S (an aqueous solution of polyacrylic acid used as a thickener; available from Rohm &
- the spun bonded polyethylene sheet material was obtained from E. I. du Pont de Nemours and identified as Type 8822 having a thickness of 4 to 5 mils and a weight of approximately 1.5 ounces per square yard.
- Saturant (a) Geon 576 (a preplasticized vinyl chloride latex having a total solids content of from 55-57.5%; pH of 8.0; surface tension of 33-40 dynes/cm.; a viscosity [Brookfield at R.T.] of 29-40 cps., the specific gravity of the latex being about 1.26; available from B. F. Goodrich Chemical Co.). Saturant weight (lbs.):
- Epi-Rez 510 an epoxy resin having a viscosity from 10,000 to 16,000 cps.; a specific gravity of 1.15-1.17 at 25 C.; an epoxide equivalent of 185-200; being the reaction product of 2 mols of epichlorohydrin with 1 mol of bisphenol A and available from Jones Dabney
- PL-S a completely polymerized long chain polyester being the reaction of about 3 mols of phthalic acid with 7 mols of adipic acid and 12 mols of propylene glycol. It has an acid value of 28-32; available from General Resin Corporation) DEH-l4 100 Methylene chloride Saturant weight (lbs.):
- Maker coat Syntex 3414 (an epoxy ester having an oil length of about 35%; 79-81% solids and an acid value of 12 maximum) 68.75 High flash naphtha 29.18 Cobalt naphthenate 1.81 Lead naphthenate 0.23
- Coated abrasive articles prepared in accordance with the foregoing examples prove to be highly flexible and supple.
- the flexibility of the spun bonded polyethylene backing impregnated with the compositions as set forth were actually more flexible and supple than the unirnpregnated material.
- the spun bonded polyethylene backing may have a thickness ranging from about 3 to about 12 mils. Materials having a thickness outside the foregoing range may be utilized although for most coated abrasives this range is quite satisfactory.
- the ratio of saturant to the spun bonded polyethylene backing by weight is approximately 1:3 to 1:2.
- a coated abrasive product comprising a backing composed of a sheet of self-bonded linear polyethylene fibers, said backing being impregnated with a material selected from the group consisting of a copolymer of vinyl chloride and vinylidene chloride and a copolymer consisting of:
- a polyamide thermoplastic resin having a molecular weight of from 3,000 to 6,000, an amine value of from about 290 to 450, and a viscosity at 25 C. in centipoises of from 200 to 1,000, the weight ratio 7 of said polyamide to said epoxy resin being about 0.5/1 to about 1/1; and (c) a long chain polyester having chain lengths of at least 14 members and being the reaction product of phthalic acid, adipic acid and propylene glycol and wherein the ratio of said polyester to said epoxy resin is about .25/1 to about 1/ 1; a layer of abrasive grains bonded to said impregnated backing by means of a polyurethane elastomeric adhesive, and a top-size coating over said grains and said polyurethane adhesive composed of an epoxy novolac resin having at least three reaction epoxy groups.
- the coated abrasive product of claim 1 wherein a fine abrasive is included into said impregnating material.
- said polyester is a long chain polyester having chain lengths of at least 14 members and being the reaction of about 3 moles of phthalic acid with 7 moles of adipic acid and 12 moles of propylene glycol and wherein the ratio of said polyester to said epoxy resin is about 1/1.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Laminated Bodies (AREA)
- Manufacture Of Macromolecular Shaped Articles (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Artificial Filaments (AREA)
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US497644A US3402034A (en) | 1965-10-19 | 1965-10-19 | Coated abrasive products |
GB43417/66A GB1164466A (en) | 1965-10-19 | 1966-09-28 | Coated Abrasive Products |
DE19661569594 DE1569594A1 (de) | 1965-10-19 | 1966-10-05 | Schmirgel-Produkte |
AT969066A AT277795B (de) | 1965-10-19 | 1966-10-17 | Überzogenes Schleifmittelprodukt |
CH1506966A CH490935A (fr) | 1965-10-19 | 1966-10-18 | Produit abrasif, procédé pour sa fabrication ainsi que l'utilisation du produit |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US497644A US3402034A (en) | 1965-10-19 | 1965-10-19 | Coated abrasive products |
Publications (1)
Publication Number | Publication Date |
---|---|
US3402034A true US3402034A (en) | 1968-09-17 |
Family
ID=23977695
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US497644A Expired - Lifetime US3402034A (en) | 1965-10-19 | 1965-10-19 | Coated abrasive products |
Country Status (5)
Country | Link |
---|---|
US (1) | US3402034A (de) |
AT (1) | AT277795B (de) |
CH (1) | CH490935A (de) |
DE (1) | DE1569594A1 (de) |
GB (1) | GB1164466A (de) |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3540869A (en) * | 1965-09-02 | 1970-11-17 | Esterol Ag | Grinding members containing a binder of a copolymer of an unsaturated polyester resin and a polymerizable ethylene derivative |
US3963458A (en) * | 1971-04-05 | 1976-06-15 | Norton Company | Coated abrasive material |
US4018574A (en) * | 1970-12-16 | 1977-04-19 | Norton Compay | Process for the manufacture of endless coated abrasive articles |
US4049396A (en) * | 1973-05-01 | 1977-09-20 | National Research Development Corporation | Molded abrasive article comprising non-foamed, friable polyurethane and process |
US4515703A (en) * | 1981-06-01 | 1985-05-07 | Lever Brothers Company | Article carrying active material |
US6672952B1 (en) | 1998-12-23 | 2004-01-06 | 3M Innovative Properties Company | Tearable abrasive article |
US20090170409A1 (en) * | 2007-12-28 | 2009-07-02 | Iv Technologies Co., Ltd. | Polishing pad and polishing method |
WO2018071361A1 (en) * | 2016-10-10 | 2018-04-19 | 3M Innovative Properties Company | Sandpaper with non-slip coating layer |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2095185A2 (en) * | 1970-07-13 | 1972-02-11 | Norton Co | Abrasive sheet |
Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2958593A (en) * | 1960-01-11 | 1960-11-01 | Minnesota Mining & Mfg | Low density open non-woven fibrous abrasive article |
US2981615A (en) * | 1959-09-08 | 1961-04-25 | Carborundum Co | Abrasive articles and method of making the same |
US3014795A (en) * | 1959-06-12 | 1961-12-26 | Raybestos Manhattan Inc | Coated abrasive products |
US3020139A (en) * | 1960-04-18 | 1962-02-06 | Norton Co | Abrasive product |
US3136614A (en) * | 1958-06-04 | 1964-06-09 | Raybestos Manhattan Inc | Coated abrasive products |
US3169899A (en) * | 1960-11-08 | 1965-02-16 | Du Pont | Nonwoven fiberous sheet of continuous strand material and the method of making same |
US3246969A (en) * | 1959-10-07 | 1966-04-19 | Minnesota Mining & Mfg | Abrasive coated backing of linear polymono-alpha-olefinic hydrocarbon |
-
1965
- 1965-10-19 US US497644A patent/US3402034A/en not_active Expired - Lifetime
-
1966
- 1966-09-28 GB GB43417/66A patent/GB1164466A/en not_active Expired
- 1966-10-05 DE DE19661569594 patent/DE1569594A1/de active Pending
- 1966-10-17 AT AT969066A patent/AT277795B/de not_active IP Right Cessation
- 1966-10-18 CH CH1506966A patent/CH490935A/fr not_active IP Right Cessation
Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3136614A (en) * | 1958-06-04 | 1964-06-09 | Raybestos Manhattan Inc | Coated abrasive products |
US3014795A (en) * | 1959-06-12 | 1961-12-26 | Raybestos Manhattan Inc | Coated abrasive products |
US2981615A (en) * | 1959-09-08 | 1961-04-25 | Carborundum Co | Abrasive articles and method of making the same |
US3246969A (en) * | 1959-10-07 | 1966-04-19 | Minnesota Mining & Mfg | Abrasive coated backing of linear polymono-alpha-olefinic hydrocarbon |
US2958593A (en) * | 1960-01-11 | 1960-11-01 | Minnesota Mining & Mfg | Low density open non-woven fibrous abrasive article |
US3020139A (en) * | 1960-04-18 | 1962-02-06 | Norton Co | Abrasive product |
US3169899A (en) * | 1960-11-08 | 1965-02-16 | Du Pont | Nonwoven fiberous sheet of continuous strand material and the method of making same |
Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3540869A (en) * | 1965-09-02 | 1970-11-17 | Esterol Ag | Grinding members containing a binder of a copolymer of an unsaturated polyester resin and a polymerizable ethylene derivative |
US4018574A (en) * | 1970-12-16 | 1977-04-19 | Norton Compay | Process for the manufacture of endless coated abrasive articles |
US3963458A (en) * | 1971-04-05 | 1976-06-15 | Norton Company | Coated abrasive material |
US4049396A (en) * | 1973-05-01 | 1977-09-20 | National Research Development Corporation | Molded abrasive article comprising non-foamed, friable polyurethane and process |
US4515703A (en) * | 1981-06-01 | 1985-05-07 | Lever Brothers Company | Article carrying active material |
US6672952B1 (en) | 1998-12-23 | 2004-01-06 | 3M Innovative Properties Company | Tearable abrasive article |
US20090170409A1 (en) * | 2007-12-28 | 2009-07-02 | Iv Technologies Co., Ltd. | Polishing pad and polishing method |
WO2018071361A1 (en) * | 2016-10-10 | 2018-04-19 | 3M Innovative Properties Company | Sandpaper with non-slip coating layer |
CN109803791A (zh) * | 2016-10-10 | 2019-05-24 | 3M创新有限公司 | 具有防滑涂层的砂纸 |
CN109803791B (zh) * | 2016-10-10 | 2021-12-10 | 3M创新有限公司 | 具有防滑涂层的砂纸 |
Also Published As
Publication number | Publication date |
---|---|
GB1164466A (en) | 1969-09-17 |
DE1569594A1 (de) | 1969-10-02 |
CH490935A (fr) | 1970-05-31 |
AT277795B (de) | 1970-01-12 |
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