WO1997019786A1 - Articles pour le conditionnement de surfaces et procedes pour les realiser - Google Patents

Articles pour le conditionnement de surfaces et procedes pour les realiser Download PDF

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Publication number
WO1997019786A1
WO1997019786A1 PCT/US1996/019188 US9619188W WO9719786A1 WO 1997019786 A1 WO1997019786 A1 WO 1997019786A1 US 9619188 W US9619188 W US 9619188W WO 9719786 A1 WO9719786 A1 WO 9719786A1
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WO
WIPO (PCT)
Prior art keywords
binder
latex
surface conditioning
web
resin
Prior art date
Application number
PCT/US1996/019188
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English (en)
Inventor
Bernard Vincent
Original Assignee
Minnesota Mining And Manufacturing Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Minnesota Mining And Manufacturing Company filed Critical Minnesota Mining And Manufacturing Company
Publication of WO1997019786A1 publication Critical patent/WO1997019786A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
    • B24D18/0027—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for by impregnation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D11/00—Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
    • B24D11/001—Manufacture of flexible abrasive materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D11/00—Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
    • B24D11/02—Backings, e.g. foils, webs, mesh fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • 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

Definitions

  • the present invention relates to surface conditioning articles formed from an organic matrix coated and engulfed by organic binders.
  • the present invention also relates to a method for making a layered composite from which a surface conditioning article may be machined.
  • Surface conditioning articles are surface treatment articles formed from an organic polymeric matrix formed of a solid or foamed organic polymer or a nonwoven fiber web find utility in treating a surface to prepare it for further coatings. Burrs and flashing from cast, drilled or punched parts must be removed to produce a desired shape or surface finish. Surface conditioning articles in the form of wheels, discs, or belts operating at high speeds and high pressures must have sufficient strength and durability when subjected to high use pressure against the workpiece. It is desirous for the article to be flexible to intrude into crevices in the workpiece. In addition, the propensity of the article to smear onto the workpiece must be taken into consideration. Smearing is generally considered deleterious.
  • the term “smear-resistant” is meant to denote embodiments of the invention exhibiting substantially no visible signs of the surface treatment article remaining on the workpiece after the workpiece article has been treated.
  • the articles of the invention call be urged against a workpiece at high operating speeds and/or pressures without smearing of the article onto the workpiece.
  • surface conditioning is used here to include all steps between preliminary removal of material and final polishing or finishing step. Those steps comprise, grinding, lapping, deburring and the like.
  • Polymeric resinous binders used to bond the matrix or to secure abrasive particles within the matrix of such products have generally been either of the hard thermosetting type or the strong, tough elastomeric type.
  • Hard thermosetting resins such as base catalyzed phenol formaldehyde, are widely used to secure abrasive particles to sheet-like backing or to the fibers of a nonwoven web.
  • Such hard resin binders while usually having high tensile strength, low elongation at break or failure, and resistance to significant change when subjected to elevated temperatures, are undesirably susceptible to brittle fracture.
  • Strong, tough elastomeric resin binders are more desirable in certain applications which require tougher, more durable surface treatment products.
  • Such elastomeric binders have excellent tensile strength, a very high elongation at break, and resistance to brittle fracture but may exhibit significant softening at elevated temperatures as might be encountered when the surface treatment article is urged against a workpiece at high speeds and pressures. Such softening may result in smearing or transfer of portions of the article to the surface of the workpiece, which as described previously is not desired by the user.
  • the product has to be flexible to be used in narrow and short belts form for example; it has to be conformable to allow uses on complicated surfaces; it has to be resistant to abrasion, and has to show resistant to brittle fracture to avoid an excessive wear of the product when used. It has to be resistant to high temperature occurring when used at high pressure/speed, and has not to let any smearing coating on the treated surfaces.
  • a "size” coating of resinous binder material and abrasive particles is applied, usually by spray-coating, over the prebonded web to increase the abrasive characteristics of the article, such as preventing the abrasive mineral from shelling. Then, the size coating is cured.
  • the resins of the various "prebond”, “slurry”, and “size” coatings may be different.
  • the prebond coat is the most important one as far as smear resistance is concerned, because it protects the fibers from softening when using the article in heavy, high pressure.
  • Phenolic resin binders in particular, are used extensively to manufacture nonwoven abrasive articles as a binder for the abrasive particles because of their thermal properties, availability, low cost, and case of handling.
  • the monomers used in greatest volume to produce phenolic resins are phenol and formaldehyde.
  • a compatibility problem arises from the use of the phenolic binder in particular together with a nonwoven web based on polyamide fibers.
  • a particularly useful known nonwoven abrasive article is one comprising a web of polyamide fibers and resole-type phenolic resins as the curable binder.
  • Such a composition provides for strong, tough, temperature resistant abrasive articles that may be made economically.
  • Rubber-modified phenolic resins have also been used in the manufacture of nonwoven abrasive articles, such as in the disclosure of commonly assigned U.S. Patent No. 2,958,593 (Hoover et al.), as an optional rubber treatment disposed on one side of the structure to increase the resistance of the overall abrasive article structure to tearing and shredding.
  • Hoover et al. Rubber-modified phenolic resins have also been used in the manufacture of nonwoven abrasive articles, such as in the disclosure of commonly assigned U.S. Patent No. 2,958,593 (Hoover et al.), as an optional rubber treatment disposed on one side of the structure to increase the resistance of the overall abrasive article structure to tearing and shredding.
  • Hoover et al. Hoover et al.
  • a nylon fiber web being first coated with a phenol-formaldehyde and amine terminated polyamide resin-containing coating, followed by transmitting the phenol exposed web to a curing oven where the coated web is so heat-treated such that the emitted treated web is cured to a nontacky state while still warm, and, only thereafter, a rubbery composition based on a butadiene acrylonitrile copolymer latex (viz. trade designation "Hycar® Latex 1561", from B.F. Goodrich Co.) is applied to the opposite side of the web and heat-cured in an oven.
  • a rubbery composition based on a butadiene acrylonitrile copolymer latex viz. trade designation "Hycar® Latex 1561", from B.F. Goodrich Co.
  • the goal of the present invention is to provide surface conditioning articles which can be urged against a workpiece at high pressure and/or high speed with no undesirable smearing or other transfer of the article to the workpiece surface.
  • the goal of the present invention is further to provide a surface conditioning article prepared with water-based formulations, said article having properties, especially, flexibility and smear resistance, equivalent to polyurethane standard reference article currently existing.
  • Water-based formulations for surface treating products having a wider range of possible use than the specific surface conditioning article of the present invention have been disclosed in U.S. 5,306,319.
  • the water-based formulations of U.S. 5,306,319 comprise binders consisting in a reaction product of polyurethane prepolymers or plurality of adducts. These adducts render the preparation method difficult and costly.
  • the properties do not totally respect all of the customers needs defined as "cut", “wear resistance”, “smear resistance” and "flexibility” for the specific field of the surface conditioning article.
  • a first aspect of the invention is a surface conditioning article comprising an organic matrix substantially engulfed by water-based organic binders including a first or "prebond" binder and a second or “slurry” binder with abrasive particles dispersed and adhered within said second binder, wherein the first binder comprises a mixture of a phenolic resin and a carboxylated butadiene-acrylonitrile copolymer latex, in the range of weight ratio of dry materials of said latex versus said phenolic resin of 90/10 to 60/40.
  • Phenolic resin provides hardness, cohesion, adhesion of the fiber web and between different layers, high thermal resistance to the coating, it is a perfect support for the layers which include minerals in abrasive applications. Phenolic may be too brittle and too hard to be used alone in an alternative coating to urethanes. Specificity of the phenolic resin used is preferably to present very high water tolerance to allow to support to be mixed with very high ratio of NBR latex dispersion and this without getting mixing compatibility problems (gellification). That is why it is necessary to have a phenolic resin no too much advanced in the condensation reaction (i.e. with a low molecular weight). Specific experiments have been needed to determine phenolic resin compatibility to NBR latex.
  • the said phenolic resin of the first binder is a resole-type phenolic resin with a water tolerance of at least 500 % by weight. More particularly, the water tolerance comprises from 500 to 2500 %. A water tolerance of 500 % by weight means that the resin can be mixed with 5 times its own weight with water without precipitations. In a preferred embodiment, said phenolic resin of the first binder has a molecular weight in the range of 100 to 1000.
  • NBR latex carboxylated butadiene-acrylonitrile latex
  • An important function of the carboxylated butadiene-acrylonitrile latex (herein after referred to as "NBR" latex) in the present invention is to provide outstanding thermal resistance for a so flexible coating. This protects the fibers from softening at high temperatures. This gives to the final product flexibility and smearing resistance in the same time. This function is linked to the way carboxylated NBR latex degrades with temperature -cyclize before being destroyed by heat by, melting- in contrast to systems where such a cyclisation is not possible. They show no residual thermoplasticity whatever; that makes for example NBR latexes highly suitable items for brake lining and clutch plate facings.
  • NBR latex provides high flexibility (Tg close to -30°C), conformability, softness, and very high resistance to flex fatigue and very good mechanical properties for such flexible coatings. It shows high resistance to abrasion and wear. It keeps high flexibility at low temperatures.
  • the latex particles have a size in the range of 10 to 500 nm.
  • the articles of the invention have a wide available range of flexibility and smear-resistance, thus making them useful in articles designed to abrade a workpiece, deburr a workpiece, wipe the surface of a workpiece, or buff a workpiece.
  • inventive binder is applied to the organic matrix in the form of an aqueous composition, thus eliminating or substantially reducing the release of volatile organic compounds in the process of making the inventive articles.
  • the carboxyl groups allow self crosslinking of the copolymer without use of catalyzing agent.
  • the organic matrix comprises an open, lofty, three- dimensional nonwoven web of the article which comprises a plurality of organic polymeric fibers bound together at points where they contact by the first binder.
  • the article comprises a third or "size" binder coated over the second binder, said third binder comprising a mixture of phenolic resin and carboxylated butadiene acrylonitrile copolymer latex.
  • the weight ratio of dry materials of said latex versus said phenolic resin in the third binder is in the range of 60/40 to 40/60.
  • the phenolic resin and carboxylated butadiene- acrylonitrile latex are the same in the first and third binders.
  • the phenolic resin of the first and third binders may be selected from commercial materials.
  • the phenolic resin of flrst and third binders may be selected from the group consisting of Lacfen 420® from (Satef Huttens Albertus Spa) and SW 378® from Bakelite and the butadiene-acrylonitrile latex is selected from the group consisting of Perbunan®,
  • N2890® from Bayer and LN 240S® from BASF.
  • the second binder of the article according to the present invention may comprise conventional water-base resole-type phenolic resin.
  • Another aspect of the invention is a method of making a layered composite from which a surface conditioning article according to the present invention may be machined, the method comprising: a) coating a major portion of the organic fibers of an open, lofty, three- dimensional nonwoven web with the first binder composition to form a first coated web; b) exposing the first coated web to energy sufficient to at least partially cure the first binder composition to form an open, lofty, three-dimensional nonwoven prebonded web of fibers; c) coating at least a portion of the fibers of the prebonded web with an aqueous slurry, comprising water, abrasive particles and a said second binder to form a second coated web; d) exposing the second coated web to energy sufficient to cure the second binder; e) coating at least a portion of the fibers of the second coated web with a third binder; f) exposing the
  • step a) the method comprises:
  • the nonwoven web may be selected from commercial materials.
  • another aspect of the invention is a method of making an open, lofty nonwoven surface conditioning article, wherein the step a) comprises two sub- steps: a) forming an open, lofty, three-dimensional nonwoven web of organic fibers; and b) entangling the organic fibers of the nonwoven web to form an entangled web having an effective density.
  • Surface conditioning articles of this inventions are suitable for use in a variety of applications. They may be adapted for use on any workpiece composition including metal, wood, plastics, composites, glass, ceramics, concrete, and others. They are designed for a use intermediate between the aggressive removal of material from a workpiece and clean a workpiece in preparation for painting, plating, etc.
  • Surface conditioning articles of the invention are especially effective in conditioning metals without substantial smearing onto the metal workpiece.
  • articles of the invention employ inventive binders which allow the articles to exhibit a high flex fatigue resistance (in other words, able to deform and penetrate into grooves and indentations in a metal workpiece, and then return to its original shape, in a cyclic process).
  • the binders may contain optional functional additives or fillers such as colorants, thickening agent, pH buffering agent and scavengers.
  • binders are applied to the organic matrix in the form of aqueous compositions (emulsions, dispersions, or slurries).
  • the aqueous compositions may comprise plasticizers, viscosity modifiers, grinding aids and abrasive particles, the latter in the case of aqueous slurries.
  • Thickeners may be used to adjust the viscosity of the aqueous or solvent dispersed binder system, i.e., when in the liquid state, in order to provide for an easily-coatable composition.
  • suitable thickeners include salt of polyacrylic acid carboxymethyl cellulose, guar gum, gum tragacanth, homo- and copolymers of poly(vinyl alcohol), methyl cellulose, modified starch, and the like.
  • the thickening agent increases viscosity of the wet mix so that sufficient weight can be applied with a roll coat process on the fiber web.
  • Suitable pH buffering agents may include materials like triethanolamine and ammonia. pH buffering agent helps thickening efficiency without leaving residual basic component in the wet coating during drying.
  • Suitable scavengers may include materials like urea, or melamine.
  • Scavengers minimize formaldehyde emissions of phenolic resins during drying.
  • colorants are inorganic pigments, organic dyes, and the like.
  • Reinforcements may include, for example, short organic or inorganic fibers, spheres, or particles. Grinding aids may be materials such as poIy(vinyl chloride), potassium fluoroborate, and the like.
  • Fillers may include calcium carbonate, fumed silica, and other materials which are primarily inert with respect to the utility of the articles.
  • Plasticizers may include, for example, phthalic acid esters, oils, and other relatively low molecular weight materials.
  • Abrasive particles are added to the binder system to render the inventive surface conditioning article more aggressive in its action on a workpiece.
  • Such abrasive particles, employed to produce the surface conditioning articles of the present invention may be any known abrasive material commonly used in the abrasive art.
  • the abrasive granule size and type may be any of those commonly used to make surface conditioning articles.
  • abrasive particles examples include silicon carbide, aluminum oxide, cerium oxide, alumina zirconia, cubic boron nitride, garnet, pumice, sand, emery, mica, flint, talc, corundum, quartz, diamond, boron carbide, fused alumina, sintered alumina, alpha-alumina-based ceramic material (available from Minnesota Mining and Manufacturing Company, Saint-Paul, MN under the trade designation "CUBITRON”), and mixtures thereof.
  • Agglomerate abrasive particles such as those described in U.S. Patents Nos. 4,652,275 and 4,799,939 may also find utility.
  • the organic matrix serves the function of providing strength and structural integrity to the surface conditioning articles of the present invention. On a more fundamental basis, the organic matrix serves the function of providing a substrate for the binders and abrasive particles.
  • the organic matrix may be either a solid of foamed organic polymer or a nonwoven web comprised of organic fibers, preferably hydrophilic organic fibers. If hydrophilic organic fibers are employed, a heating step may be eliminated or reduced as the fibers will absorb water from the emulsified binder.
  • An example of a lofty, nonwoven web formed of crimped staple fibers adhered at points of contact with binder which contains abrasive particles is taught in U.S. Patent No. 2,958,593 (Hoover et al.).
  • U.S. Patent No. 4,227,350 discloses a matrix formed of three-dimensionally undulated inter-engaged autogenously bonded continuous filaments.
  • the organic matrix may be comprised of thermoplastic organic staple fibers, such is nylon (polyamide), polyester, and the like staple fibers or a combination of thermoplastic and cellulosic staple fibers, such as viscose rayon, and the like.
  • thermoplastic fibers are nylon staple fibers, especially nylon 6,6. If a combination of thermoplastic organic fibers and cellulosic fibers are employed the weight of cellulosic fibers as a percentage of the total fibers weight may range from about 5 weight percent to about 50 weight percent.
  • said open, lofty, three-dimensional nonwoven web comprises organic polyester or polyamid fibers.
  • the fibers preferably have denier ranging from about 10 to 100 and length ranging from about 10 to 100 mm.
  • Surface conditioning articles within the present invention may take any of a variety of conventional forms such as sheets, blocks, strips, belts, brushes, rotary flaps, discs, or solid or foamed wheels.
  • Especially useful forms are wheels in the form of a disc or right circular cylinder having dimensions which may be very small, e.g., a cylinder height on the order of a few millimeters, or very large, e.g., two meters or more, and a diameter which may be very small, e.g., on the order of a few centimeters, or very large, e.g., one meter or more.
  • the wheels typically have a central opening for support by an appropriate arbor or other mechanical holding means to enable the wheel to be rotated in use.
  • Wheel dimensions, configurations, means of support, and means of rotation are well known in the art.
  • a useful summary of various wheel forms of surface treatment articles which may be made using the inventive binders are described in the publication "3M Wheels", published in 1990 by Minnesota Mining and Manufacturing Company, Saint Paul, MN ("3M"), which is incorporated herein by reference.
  • Surface treatment articles of the present invention in which the organic matrix is engulfed by a binder may be prepared by forming a layered composite.
  • Layered composites (known in the art as "slabs") may be produced by cutting, punching, or otherwise machining uncured or partially cured webs into sheets or discs which are then overlapped on one another and then compressed and cured to make a higher density, slab. Such cutting, punching and other machining techniques are well known to those skilled in the art.
  • a layered composite may be used as the source of a multitude of articles of the invention each having various diameters, or all the same diameter, as required by the user.
  • Article of the invention may be produced form the layered composites by machining using appropriate techniques which are also well known in the art. For example, a wheel shape may be die cut from a slab of the layered composite. Additionally, ribbons, strips, or elongate segments of the layered composite may be spirally wound into a wheel shape while the binder is uncured or partially cured and then fully cured to yield a wheel.
  • Figure 1 represents the results of the prebond study of flexibility versus latex/resin dry ratio of the example products.
  • Figure 2 represents the results of the preferred study of the wear resistance versus latex resin dry ratio of the example products.
  • Figure 3 represents the results of the prebond study of the "cut” versus latex/resin dry ratio of the example products.
  • Figure 4 represents the results of roughness measurements versus latex resin dry ratio of the size binder at the "size" level of the example products.
  • Figure 5 represents the results of the effect on disc “wear” versus the dry ratio latex/resin at the "size” level of the example products.
  • Figure 6 represents the effect on "cut” versus the dry ratio latex/resin at the "size” level of the example products.
  • Fiber web forming A non woven web is formed on a basis of nylon fibers (polyester or other types could be used too) dimensions of the fibers can go from about ten to several hundred deniers for the diameter and from about several ten to several hundred mm for the length, they can be crimped or not.
  • the web can be made with several processes: air laid (Rando), carding, cross lapping, needle tacking.
  • a woven scrim (Nylon, DEF, or other type of fabrics) can be used as an "inside" basis to consolidate the nonwoven web, the cloth can be included to the web by Needle tacking for example.
  • the fiber web forming is made as follows.
  • the web fiber is made of Nylon fiber (Supplier: Wellman International Ltd), 60 deniers and 100 deniers fibers are used, length of these staple fibers are approximately 76mm.
  • the web is preformed on a carding machine (from OCTIR Spa Italia), eight layers are made with a cross lapping machine (from ASSELIN France) to consolidate the fiber web. Its weight is about 300/350 g/m 2 .
  • the web is then needle tacked on a Needle tacking machine (from FEHRER AG Austria); the fiber web is needle tacked on a Nylon (or PET) woven fabrics (described hereafter in a Raw Material list) of 150 g/m 2 which upgraded the use of the final product in belts applications.
  • the web thickness is from 5 to 15mm depending of the product grade made.
  • Prebond Roll coat The fiber web is saturated in its thickness with a polymers-system applied with a roll coating process. Generally, the coating used provides to the product flexibility and conformability but in the same time mechanical and thermal resistance characteristics needed for the final product application at high speed and pressure.
  • the coated prebond weight is adapted to the fiber web design so that correct fibers saturation is achieved (i.e. about ten to several thousands grams per square meters).
  • the coating is then dried in an oven with temperatures about 90 to 170°C and times above ten minute so that untacky material can be usable for the next step. More particularly, in the hereinafter detailed examples the prebond step is dried at 90/110°C during 15mn.
  • Slurry spray the previous prebond is then sprayed oil one side surface with a mix generally made with both basic components Phenolic resin and the abrasives particles.
  • the coating used provides high mechanical and thermal resistance characteristics needed for the final product application at high speed and pressure, especially "cut” and "wear resistance”.
  • the sprayed slurry weight is adapted to the application needs (i.e. about ten to several thousands grains per square meters).
  • the coating is then dried in an oven with temperatures about 100 to 170°C and times less than ten minutes to provide enough energy so that resin cure can be completed. More particularly, in the hereinafter detailed examples, the slurry spray step is dried at 100/145°C during 6mn.
  • Size spray The previous material is a new time sprayed on the same side surface with a mix made with a polymeric system. Generally the coating used must provide an outside layer which can protect the previous mineral coating of an excessive initial wear during use at high speed and pressure.
  • the coated size spray weight must be adapted to the application needs (about ten to several thousands grams per square meters).
  • the coating is then dried in an oven with temperatures about 100 to 170°C and times more than one hour to provide enough energy so that resin cure can be completed. More particularly, in the hereinafter detailed examples, the size step (and the completed product) is cured at 100/145°C during 2 hours.
  • the product in a jumbo form can be converted in a very wide forms range: for example discs, belts, hand pads, rolls, wheels, brushes.
  • Performance test in belt form "cut” and "wear”: Product is converted in an endless belt form with following dimensions 2500 mm long per 50 mm width. A rectangular piece of material is cut in tile length direction, the dimension of the piece depends of the dimensions of the belts needed. Then both extremities of the rectangular product piece are joined and glued by an adhesive which will provide sufficient adhesion so that the splice will stay glued during application. Belt is placed on a hackstand machine. Machine speed is 2830 rpm, contact wheel is rubber made with a hardness range of 80/90 shores and a diameter of about 200 mm; it presents serrated valleys at 1/1 ratio with an angle of 45°.
  • Grinding materials used are steel bars (XC 38 ref.) dimensions are 200 mm long per 20 mm diameter. Bars, placed in a holder, are presented its length to the belts in an horizontal way.
  • Pressure used for grinding is 5.8 kg for the 50 mm belt width.
  • Running cycle is 30 seconds, and is repeated 24 times on a different bar face (4 per bar).
  • Performance test in disc form "cut” and “wear”: Product is concerted in a disc form of 178 mm diameter with a centered hole and fix on a holder (3M Brand Disc Pad holder European ref. 09921).
  • a pneumatic portable machine (type Brand G. Renoult PL 120 with an operating speed of 2000 rpm) is used to perform the test. This pneumatic device is mounted on a robotics station
  • the portable tool with a disc mounted on it is presented by the robotics-station to a holder which supports 20 stainless steels sheets. These sheets (30x80x1 mm) are 5 mm spaced from one to the other and are placed in vertical way, the length inside the holder.
  • the running disc grinds these sheets on the sharpest side from left to right, and this two times. Pressure is approx 4 kg and running speed approx. 16 mm per seconds, angle between disc and floor is close to 7°.
  • the loss of removed steel on each bars is measured and reported as "cut”
  • the loss of the belt weight is measured at the end of the test and reported as "wear”
  • "efficiency” represents the ratio "cut wear”.
  • “Cut” is the quantity of material which is removed from the grinded piece during the time the test is performed. This "cut” is calculated by comparing the weight of the bars before and after the test. The number represents the ability, of the abrasive product to remove material like rust or paint during typical applications.
  • Weight is the quantity of material that the abrasive product (belt or disc forms) is losing during the time the test is performed.
  • the “wear” is calculated by comparing the weight of the samples before and after the test, and then divided by the initial material weight (results in %). This number represents the life time of the product, as the more the product will “wear”, the less it will be used in terms of time units during when the product is usable.
  • Performance test hand tool evaluation (in disc form): Product is converted in a disc form of 178 mm diameter without centered hole and fix on a holder (3M Brand disc Pad holder ref. 0917). A pneumatic portable machine (type Brand G. Renault PL120 with an operating speed of 2000 rpm) is used to perform the test. An operator performs the tests following usual uses of the product application. Edge resistance is visually evaluated after having grinded the edge of a carbon steel block during approx 20 seconds. Performance of the product is represented by the time needed to remove the paint coating from a standard painted sheet used for automotive applications. Loading resistance is visually evaluated after having removed this paint coating. Smearing resistance can be visually evaluated by looking if the disc has left a "smearing coating" on simple stainless sheet and with heavier hand pressure.
  • Performance test finish & smearing resistance evaluation: Product is converted in a disc form of 178 mm diameter without centered hole and fix on a holder (3M Brand disc Pad holder ref. 0917).
  • a pneumatic portable machine (type Brand G. Renault PL 120 with an operating speed of 2000 rpm) is used to perform the test. This pneumatic device is mounted on a robotics station (type Brand ABB 3000 equipped with a compliance system which controls pressure).
  • the portable tool with a disc mounted on it is presented by the robotics station to a stainless steel sheet of 50x50 cm with an initial finish quality reference 2B.
  • the machine performs two runs on the metal from top to bottom with a rotating speed of 2000 rpm, length of the grinded metal is approx. 30 cm in approx. 15 seconds, pressure is controlled to 4 kg and running angle is close to 7°.
  • Finish level is evaluated with roughness measurements oil a Perthometer device (ref. PRK S8P from Mahr Perthen Cy -G ⁇ ttlinger-D3400 Germany); the roughness values Ra, Rz and Rmax are registered.
  • Smearing resistance is visually evaluated by looking if the disc has left a "smearing coating" on the stainless sheet.
  • This product is the current existing standard product made in a 3M US plant (Prairie du Chien WI).
  • the design described is defined for product called "SC A Coarse with scrim".
  • the fiber used is a mixture of 70 to 58 deniers type needle tacked on a nylon open scrim.
  • Prebond roll coat formulation is based on the use of flexible urethane resin (BL 16 adiprene from Uniroyal Inc.) catalyzed by methylene dianiline (MDA in PM acetate solvent).
  • PM acetate solvent is used for adapting viscosity to coating process.
  • Lithium stearate is used for helping in smearing resistance during use at high pressure/ speed producing elevated temperatures. Brown pigment is used for appearance reason.
  • Slurry spray is made with 80 grit A1203 with phenolic resin to bond mineral together and mineral to previous layers. Epicure® is used as a phenolic resin curing agent.
  • PM ether solvent is used for adapting viscosity to spraying process.
  • Lube premix is used for helping in smearing resistance during use at high pressure/speed producing elevated temperatures.
  • Other "grades" of products like medium or fine type use finer minerals.
  • Size spray formulation is based on the use of flexible urethane resin (BL31 adiprene from Uniroyal Inc.) catalyzed by methylene dianiline (MDA in PM acetate solvent). PM acetate solvent is used for adapting viscosity to coating process. Size cannot be made on other grades products.
  • ADIPRENE BL16 and BL31 are ketoxime blocked isocyanate prepolymers available from UNIROYAL Corp. Middlebury CY.
  • MDA in PM acetate solution is a mix of 35 % MDA in 65 % PM acetate solvent.
  • MDA is p, p' methylene dianiline available from CIBA GEIGY Corp. Crimsby,
  • PM acetate is Propylene monomethylether acetate available under the trade designation "Dowanol PMA” from Dow Chemicals USA Midland MI.
  • Lithium stearate premix is a mix made of 44 % of lithium stearate and 56 % of
  • Lithium stearate is available under trade designation “type FS” from Witco Corp.
  • Ace lube premix is a mix made of 80 % of "ACELUBE 23N” hydrocarbon distillate (from Gopher Oil Cy Minneapolis, MN) and 20 % of 325 mesh bentonite
  • EPICURE 852 is an amine functional curing agent from Rhone Poulenc Inc.
  • SC A Coarse with scrim are called "SC A Coarse with scrim".
  • the fibers used are 60 or 100 deniers type and the scrim nylon or PET depending of the example references.
  • Prebond roll coat formulation is based on the use of flexible system based on a mix of high water tolerant phenolic resin and NBR latex. This mix, because of raw materials properties, is particularly designed to provide high smearing resistance during use at high pressure/speed producing elevated temperatures.
  • Additive like thickening agent (with Triethanolamine as pH buffer) is used for adapting viscosity to coating process and for mix stability.
  • Additive like melamine and urea are used as formaldehyde emissions (from phenolic resin) as scavengers. Brown pigment is used for appearance reason. Dry ratio phenolic resin to NBR latex are different depending of the example references.
  • Slurry spray is made with a mix of 80 A1203 grit with phenolic resin to bond minerals together and mineral to previous layers.
  • Calcium carbonate is used to get a constant mix.
  • Additives like carboxymethylcellulose (CMC) and acrylic resin are used to help to avoid minerals settling down in the wet mix. Water is used for adapting viscosity to spraying process.
  • Additive like melamine is used as formaldehyde emissions (from phenolic resin) as a scavenger. Brown pigment is used for appearance reason.
  • Other "grades" of products like medium or fine type use finer minerals.
  • Other mineral types or mixes can be used depending of example references.
  • Size spray formulation is based on the use of flexible system based on a mix of high water tolerant phenolic resin and NBR latex. This mix, because of raw materials properties, is particularly designed to provide high smearing resistance during use at high pressure/speed producing elevated temperatures. Water is used for adapting viscosity to coating process. Additive like triethanolamine (as pH buffer) is used for mix stability. Additive like melamine is used as formaldehyde emissions (from phenolic resin) as scavengers. Brown pigment is used for appearance reason. Size cannot be made on other grades products.
  • Dispersion type anionic/non anionic
  • Brookfield viscosity approx 14 cps
  • Polyester terephtalate (PET) Polyester terephtalate
  • Example 1 is a full latex NBR coated prebond
  • Example 2 is a prebond made with a dry ratio of 90 of latex and 10 of resin
  • Example 3 is a prebond made with a dry ratio of 70 of latex and 30 of resin
  • Example 4 is a prebond made with a dry ratio of 50 of latex and 50 of resin
  • Example 5 is a prebond made with a dry ratio of 30 of latex and 70 of resin.
  • R-M means "Raw materials”.
  • DRY RATIOS Prebond: 90/10 latex/resin Size: 60/40 latex/resin
  • DRY RATIOS Prebond: 70/30 latex/resin Size: 60/40 latex/resin
  • DRY RATIOS Prebond: 50/50 latex/resin Size: 60/40 latex/resin
  • DRY RATIOS Prebond: 30/70 latex/resin Size: 60/40 latex/resin
  • Example 6 is a full latex NBR sprayed size
  • Example 7 is a size made with a dry ration of 80 of latex and 20 of resin
  • Example 8 is a size made with a dry ration of 60 of latex and 40 of resin
  • Example 9 is a size made with a dry ration of 40 of latex and 60 of resin
  • Example 10 is a size made with a dry ration of 20 of latex and 80 of resin
  • Example 11 is a full phenolic resin sprayed size.
  • Products made with 60/40 and 40/60 latex/resin size sprays are showing the best wear resistance results. Products made with 60/40 and 40/60 latex/resin size sprays are showing the lowest roughness values so achieve the best finish results. "Cut" tendency is to increase with the amount of phenolic resin in the size mix. Flexibility is not affected by size ratio modifications. None of the products are showing "smearing”. In conclusion, products made with size dry ratio latex/resin from 60/40 to
  • DRY RATIOS Prebond: 90/10 latex/resin Size: 80/20 latex/resin
  • DRY RATIOS Prebond. 90/10 latex/resin Size: 60/40 latex/resin
  • DRY RATIOS Prebond: 90/10 latex/resin Size: 40/60 latex/resin
  • DRY RATIOS Prebond: 90/10 latex/resin Size: 20/80 latex/resin
  • Example 12 is a full latex NBR sprayed size.
  • Example 13 is a size made with a dry ratio of 60 of latex and 40 of resin.
  • Example 14 is a size made with a dry ratio of 30 of latex arid 70 of resin.
  • DRY RATIOS Prebond: 70/30 latex/resin Size: 100 latex
  • DRY RATIOS Prebond. 70/30 latex/resin Size: 60/40 latex/resin
  • DRY RATIOS Prebond: 70/30 latex/resin Size: 30/70 latex/resin
  • DRY RATIOS Prebond: urethane resin - reference

Abstract

L'invention concerne un article pour le conditionnement de surfaces comprenant une matrice organique noyée dans des liants organiques à base d'eau. Les liants organiques sont constitués d'un premier liant comprenant une résine phénolique et un latex d'un copolymère acrylonitrile-butadiène carboxylé et d'un second liant contenant des particules abrasives dispersées.
PCT/US1996/019188 1995-11-28 1996-11-27 Articles pour le conditionnement de surfaces et procedes pour les realiser WO1997019786A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP95402676.1 1995-11-28
EP19950402676 EP0776733B1 (fr) 1995-11-28 1995-11-28 Feuille abrasive pour traitement de surface et procédé pour sa production

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US09/906,498 Continuation US20020014040A1 (en) 1998-05-15 2001-07-16 Surface conditioning articles and method of making same

Publications (1)

Publication Number Publication Date
WO1997019786A1 true WO1997019786A1 (fr) 1997-06-05

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EP (1) EP0776733B1 (fr)
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WO (1) WO1997019786A1 (fr)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2625002B1 (fr) * 2010-10-06 2018-06-13 Saint-Gobain Abrasives, Inc. Composite non-tissé abrasif comprenant des particules abrasives de diamant
CN102039561B (zh) * 2010-10-15 2012-08-08 江苏省新型复合研磨材料及制品工程技术研究中心 高精度pcb板专用研磨材料及制造方法
CN101966694B (zh) * 2010-10-15 2012-03-28 江苏省新型复合研磨材料及制品工程技术研究中心 高效能弹性复合研磨片及其制备方法
EP3826805A1 (fr) 2018-07-23 2021-06-02 3M Innovative Properties Company Articles comprenant un support en polyester et une couche d'apprêt, et procédés associés
TR201903909A2 (tr) * 2019-03-15 2020-10-21 Cukurova Kimya Enduestrisi A S Aşındırıcı elemanlar için bir reçine ve bunun için bir üretim yöntemi.

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JPS525373A (en) * 1975-07-02 1977-01-17 Japan Vilene Co Ltd Manufacture of rough textured unwoven fabrics
FR2346106A1 (fr) * 1976-03-31 1977-10-28 Norton Co Support d'abrasif applique
SU1134579A1 (ru) * 1983-02-09 1985-01-15 Украинский Филиал Всесоюзного Научно-Исследовательского Института Абразивов И Шлифования Способ получени основы шлифовальной шкурки
EP0139309A2 (fr) * 1983-10-04 1985-05-02 Rütgerswerke Aktiengesellschaft Adhésif à plusieurs constituants ayant une conservation en pot prolongée
SU1509239A1 (ru) * 1986-06-18 1989-09-23 Тираспольский Завод "Молдавизолит" Состав дл изготовлени абразивного инструмента
DE4138717A1 (de) * 1991-11-21 1993-05-27 Axel Klauke Verfahren zur impraegnierung von glasseidengewebe mit einer modifizierten waessrigen dispersion

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JPS525373A (en) * 1975-07-02 1977-01-17 Japan Vilene Co Ltd Manufacture of rough textured unwoven fabrics
FR2346106A1 (fr) * 1976-03-31 1977-10-28 Norton Co Support d'abrasif applique
SU1134579A1 (ru) * 1983-02-09 1985-01-15 Украинский Филиал Всесоюзного Научно-Исследовательского Института Абразивов И Шлифования Способ получени основы шлифовальной шкурки
EP0139309A2 (fr) * 1983-10-04 1985-05-02 Rütgerswerke Aktiengesellschaft Adhésif à plusieurs constituants ayant une conservation en pot prolongée
SU1509239A1 (ru) * 1986-06-18 1989-09-23 Тираспольский Завод "Молдавизолит" Состав дл изготовлени абразивного инструмента
DE4138717A1 (de) * 1991-11-21 1993-05-27 Axel Klauke Verfahren zur impraegnierung von glasseidengewebe mit einer modifizierten waessrigen dispersion

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JOHN D. FISHER (SCHNECTADY CHEMICALS INC.): "WATER COMPATIBLE PHENOLIC RESINS", PROCEEDINGS OF THE AMERICAN CHEMICAL SOCIETY, DIVISION OF POLYMERIC MATERIALS : SCIENCE AND ENGINEERING . SPRING MEETING 1991, vol. 64, 1991, ATLANTA, GEORGIA, USA, pages 275 - 276, XP000561766 *
PROFESSOR DR. GERHARD W. BECKER, PROFESSOR DR. DIETRICH BRAUN; (COORDINATOR FOR VOL. 10) PROFESSOR DR. WILBRAND WOEBCKEN: "KUNSTSTOFF HANDBUCH - VOLUME 10 - DUROPLASTE", 1988, CARL HANSER VERLAG, MÜNCHEN, DE, XP002003995 *

Also Published As

Publication number Publication date
EP0776733A1 (fr) 1997-06-04
DE69528370D1 (de) 2002-10-31
EP0776733B1 (fr) 2002-09-25
DE69528370T2 (de) 2003-06-05

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