KR20160147700A - Flexible abrasive article and method of using the same - Google Patents

Abstract

The flexible abrasive article comprises a single backing having a first major surface and a second major surface facing away from each other and comprising polyurethane. In some embodiments, the backing has an average thickness of 4 to 6 mils (102 to 152 micrometers), a tensile strength of 500 to 3200 psi (3.45 to 22.1 MPa), and an ultimate elongation of 230 to 530%. In some embodiments, the flexible abrasive article has a tensile strength of 400 to 2400 psi (2.8 to 16.5 MPa) and an ultimate elongation of 180 to 380%. The polishing layer is disposed on and fixed to a single backing.

Description

TECHNICAL FIELD [0001] The present invention relates to a flexible abrasive article and a method of using the same,

Sandpaper is widely sold at home improvement and hardware stores for residential sanding applications. Common household substrates that are sanded include, for example, molding, raised panels, carving, and fluting. It is common for the user to fold / fold or wrap the sandpaper around the user's fingertip, for better control and to be able to get into the cramped area. However, such is not ideal due to the stiffness of a typical paper-backed sandpaper; In fact, it is possible to cause cracks in the sandpaper to reduce the life of the product.

The inventors have overcome the drawbacks described above by producing flexible abrasive articles comprising flexible and durable backings comprising polyurethane.

Advantageously, the flexible abrasive article can last up to 1600% longer than conventional sandpaper sold in the residential improvement market. In addition, the flexible abrasive article is sufficiently flexible to be highly suitable for sanding complex details in wood construction elements such as molding, protruding panels, carving, fluting, etc., and for excellent control and cramping Folded or wrapped around the user ' s fingertip easily and comfortably in order to be able to get in.

In one aspect, the present invention provides, as a flexible abrasive article,

Having a first major surface and a second major surface facing each other and comprising polyurethane and having an average thickness of from 4 to 6 mils (102 to 152 micrometers), an average thickness of from 500 to 3200 psi A unitary backing having a tensile strength of 3.45 to 22.1 MPa per inch and an ultimate elongation of 230 to 530%; And

And an abrasive layer disposed on and fixed to the single backing,

The polishing layer

A make layer comprising a polymerized reaction product of components comprising at least one polyepoxide and at least one polyfunctional (meth) acrylate, disposed on at least a portion of the first major surface of the single backing, );

Abrasive particles fixed to the make layer; And

A make layer and at least a portion of the abrasive particles,

A size layer comprising polymerized reaction products of components comprising at least one polyepoxide and at least one polyfunctional (meth) acrylate,

Wherein the second major surface of the single backing forms an outer major surface of the flexible abrasive article.

In another aspect, the present invention provides a flexible abrasive article,

A single backing having a first major surface and a second major surface facing away from each other, comprising polyurethane and having an average thickness of from 4 to 6 mils (102 to 152 micrometers); And

And an abrasive layer disposed on and fixed to the single backing,

The polishing layer

A makeup layer disposed on at least a portion of the first major surface of the single backing and comprising a polymerized reaction product of components comprising at least one polyepoxide and at least one multifunctional (meth) acrylate;

Abrasive particles fixed to the make layer; And

A make layer and at least a portion of the abrasive particles,

A size layer comprising a polymerized reaction product of components comprising at least one polyepoxide and at least one polyfunctional (meth) acrylate,

The second major surface of the single backing forms an outer major surface of the flexible abrasive article;

Wherein the flexible abrasive article has a tensile strength of 400 to 2400 psi (2.8 to 16.5 MPa) and an ultimate elongation of 180 to 380%.

In another aspect, the present invention provides a method of polishing a workpiece,

Providing a flexible abrasive article according to the present invention;

Frictionally contacting at least a portion of the abrasive layer with the surface of the workpiece; And

And moving at least one of the surface of the polishing layer or the workpiece to polish the surface of the workpiece.

As used herein: < RTI ID = 0.0 >

The prefix "(meth) acryl" refers to acrylic, methacrylic, or both;

The term "polyepoxide" refers to a compound having two or more epoxy groups;

The term "polyfunctional poly (meth) acrylate" refers to a compound having two or more (meth) acrylate groups;

The term "tensile strength" refers to the breaking tensile strength, unless otherwise specified.

In this application, the elongation at break and the tensile strength are determined by ASTM International Test Method D882-12, published September 2012 by ASTM International, West Conshohocken, Pennsylvania, USA, for tensile properties of thin plastic sheeting Standard Test Method for Tensile Properties of Thin Plastic Sheeting ".

The features and advantages of the present invention will be further understood in consideration of the detailed description as well as the appended claims.

1 is a schematic side view of a flexible abrasive article 100 according to the present invention.
It should be understood that numerous other modifications and embodiments that fall within the spirit and scope of the principles of the invention may be devised by those skilled in the art. The drawings may not be drawn to scale.

Referring now to FIG. 1, a flexible abrasive article 100 includes a single polyurethane backing 110 having a first major surface 115 and a second major surface 117 facing away from each other. The abrasive layer 120 is disposed on and secured to the first major surface 115 of the single polyurethane backing 110. The abrasive layer 120 includes a make layer 130, abrasive particles 140 and a size layer 150 disposed on the make layer 130 and the abrasive particles 140. An optional supersize layer (160) is disposed on the size layer (150).

The backing may have a number of physical properties that collectively impart flexibility and durability to the flexible abrasive article.

In the first embodiment, the backing is in the range of 4 to 6 mils (102 to 152 micrometers), preferably 4.5 to 6.5 mils (114 to 165 micrometers), and more preferably 4.8 to 6.2 mils ). ≪ / RTI > In this embodiment, the backing has a tensile strength in the range of 500 to 3200 psi (3.4 to 22.1 MPa), preferably 1000 to 2500 psi (6.9 to 17.2 MPa), more preferably 1600 to 2100 psi (11.0 to 14.5 MPa) Strength and an ultimate elongation (i.e., elongation at break) of 230 to 530%, preferably 300 to 460%, and more preferably 350 to 410%.

In a second embodiment, the backing is between 4 and 6 mils (102 to 152 micrometers), preferably between 4.5 and 6.5 mils (114 to 165 micrometers), and more preferably between 4.8 and 6.2 mils ). ≪ / RTI > In this embodiment, the backing has a pore size of 500 to 3200 psi (3.4 to 22.1 MPa), preferably 1000 to 2500 psi (6.9 to 17.2 MPa), more preferably 1600 to 2100 psi (11.0 to 14.5 MPa ) And an average ultimate elongation (i.e., elongation at break) of from 230 to 530%, preferably from 300 to 460%, and more preferably from 350 to 410%.

In a third embodiment, the backing has a length of 4 to 6 mils (102 to 152 micrometers), preferably 4.5 to 6.5 mils (114 to 165 micrometers), and more preferably 4.8 to 6.2 mils ). ≪ / RTI > In this embodiment, the backing has a pore size of 500 to 3200 psi (3.4 to 22.1 MPa), preferably 1000 to 2500 psi (6.9 to 17.2 MPa), more preferably 1600 to 2100 psi (11.0 to 14.5 MPa ), And optionally a minimum tensile strength, and a maximum of 230 to 530%, preferably 300 to 460%, and more preferably 350 to 410%, and optionally a minimum extreme elongation ).

In a fourth embodiment, the backing is between 4 and 6 mils (102 to 152 micrometers), preferably between 4.5 and 6.5 mils (114 to 165 micrometers), and more preferably between 4.8 and 6.2 mils ). ≪ / RTI > In this embodiment, the flexible abrasive article has a pore size of at least 400 psi (2.8 MPa), at least 500 psi (3.4 MPa), at least 600 psi (4.1 MPa), at least 700 psi (4.8 MPa), at least 800 psi Or greater than 900 psi (6.2 MPa), 1000 psi (6.9 MPa), 1100 psi (7.6 MPa), 1200 psi (8.3 MPa), or even 1300 psi (9.0 MPa) psi (11.0 MPa) or lower, 1700 psi (11.7 MPa) or lower, 1800 psi (12.4 MPa) or lower, 1900 psi (13.1 MPa) or lower, 2000 psi (13.8 MPa) or lower, 2100 psi 15.1 MPa) or less, 2300 psi (15.9 MPa) or less, or even 2400 psi (16.5 MPa) or less, or any combination thereof, and the flexible abrasive article may have a tensile strength of 180 or more, 190 or more, 200 or more , 210 or more, 220 or more, 230 or more, 240 or more, 250 or more, 260 or more, or even 270 to 340%, 350% or less, 360% or less, 370% or even 380% Ultimate elongation Have.

In a fifth embodiment, the backing is in the range of 4 to 6 mils (102 to 152 micrometers), preferably 4.5 to 6.5 mils (114 to 165 micrometers), and more preferably 4.8 to 6.2 mils ). ≪ / RTI > In this embodiment, the flexible abrasive article has a pore size of at least 400 psi (2.8 MPa), at least 500 psi (3.4 MPa), at least 600 psi (4.1 MPa), at least 700 psi (4.8 MPa), at least 800 psi Or greater than 900 psi (6.2 MPa), 1000 psi (6.9 MPa), 1100 psi (7.6 MPa), 1200 psi (8.3 MPa), or even 1300 psi (9.0 MPa) psi (11.0 MPa) or lower, 1700 psi (11.7 MPa) or lower, 1800 psi (12.4 MPa) or lower, 1900 psi (13.1 MPa) or lower, 2000 psi (13.8 MPa) or lower, 2100 psi 15.1 MPa) or less, 2300 psi (15.9 MPa) or less, or even 2400 psi (16.5 MPa) or less, or any combination thereof, and the flexible abrasive article may have an average tensile strength of 180 or more, 190 or more, 200 Or more, 210 or more, 220 or more, 230 or more, 240 or more, 250 or more, 260 or more, or even 270 or more and 340 or less, 350 or less, 360 or less, 370 or even 380% Extreme kite of It has a ratio.

In the sixth embodiment, the backing is in the range of 4 to 6 mils (102 to 152 micrometers), preferably 4.5 to 6.5 mils (114 to 165 micrometers), and more preferably 4.8 to 6.2 mils ). ≪ / RTI > In this embodiment, the flexible abrasive article has a pore size of at least 400 psi (2.8 MPa), at least 500 psi (3.4 MPa), at least 600 psi (4.1 MPa), at least 700 psi (4.8 MPa), at least 800 psi Or greater than 900 psi (6.2 MPa), 1000 psi (6.9 MPa), 1100 psi (7.6 MPa), 1200 psi (8.3 MPa), or even 1300 psi (9.0 MPa) psi (11.0 MPa) or lower, 1700 psi (11.7 MPa) or lower, 1800 psi (12.4 MPa) or lower, 1900 psi (13.1 MPa) or lower, 2000 psi (13.8 MPa) or lower, 2100 psi 15.1 MPa) or less, 2300 psi (15.9 MPa) or less, or even 2400 psi (16.5 MPa) or less, or any combination thereof, and the flexible abrasive article may have a tensile strength of at least 180 , 190 or more, 200 or more, 210 or more, 220 or more, 230 or more, 240 or more, 250 or more, 260 or more, or 270 or more and 340 or less, 350 or less, 360 or less, 370% or even 380% , Or these Lt; RTI ID = 0.0 > elongation. ≪ / RTI >

The backing may be a single; That is, the backing may be a single layer, but in some embodiments, it may be a composite backing if desired. Typically, the backing is at least substantially homogeneous, but this is not necessary. The backing can be perforated, but if perforated, the average thickness is determined without using a perforated area, in which case the perforation will have a thickness of zero, as there is no backing in the perforation. Desirably, the backing is impervious to liquid water, wherein the backing is substantially free of voids, but a small amount of porosity may be acceptable. For example, the backing may have a specific porosity of less than 10%, less than 2%, less than 1%, or even less than 0.01% based on the total volume of the backing (i.e., not intentionally added, A characteristic pore).

The backing may comprise one or more polyurethanes. Preferably, the polyurethane comprises, or at least consists essentially of, one or more thermoplastic polyurethanes (TPU). The term "essentially consisting of" when used in this context means that the presence of an additive compound (e.g., a perfume, a colorant, an antioxidant, a UV light stabilizer, and / or a filler) causes tensile strength and ultimate elongation to be substantially This means that such additive compounds may be present in the backing as long as they remain unaffected. For example, the additive may have an impact of less than 5%, preferably less than 1%, with respect to tensile strength and ultimate elongation.

In some embodiments, the backing may comprise a single thermoplastic polyurethane or a combination of thermoplastic polyurethanes. One preferred class of polyurethane is an aromatic polyether-based polyurethane, preferably a thermoplastic polyether-based polyurethane. In some embodiments, the thermoplastic polyether-based polyurethane is derived from 4,4'-methylene dicyclohexyldiisocyanate (MDI), polyether polyol, and butane diol.

Thermoplastic polyurethanes are well known and can be prepared according to a number of known techniques or can be obtained from commercial sources. For example, Lubrizol Corp. of Cleveland, Ohio, USA, for example, under the trade designation "ESTANE GP TPU (B series)" , 60 DB, 72 DB, 80 AB, 85 AB, and 95 AB); 5822, 58216, 58211, 58212, 58213, 58215, 58219, 58226, 58214, 58137, , 58237, 58238, 58244, 58245, 58246, 58248, 58252, 58271, 58277, 58280, 58284, 58300, 58309, 58311, 58315, 58325, 58370, 58437, 58610, 58630, 58810, 58863, 58881, Such as polyesters and polyether-based TPUs, which are commercially available.

The backing can be cast (e. G., From a solvent or water) or extruded. The backing may contain one or more additives, for example, fillers, melt processing aids, antioxidants, flame retardants, colorants, or ultraviolet light stabilizers.

The make layer and the size layer can be prepared by curing the respective make layer precursor and the size layer precursor. The make layer precursor and the size layer precursor can have the same or different composition and can be applied with the same or different coat weights.

The make and size layers may comprise one or more polyepoxides and one or more polyfunctional (meth) acrylates, a curing agent (e.g., a polyamine, polythiol, acid catalyst, or photocatalyst) for the polyepoxide, and a free radical initiator (Photoinitiators and / or thermal initiators). Monofunctional epoxides and polyols (e.g., diols used as chain extenders) can also be used in combination with the polyepoxide (s).

The useful polyepoxide may be aromatic or aliphatic polyepoxide (s), or a combination thereof. The useful polyepoxide may be liquid or solid, but is typically liquid for ease of handling. Whether liquid or solid, the polyepoxide (s) should generally be chosen to be soluble in the precursor composition (e.g., the make layer precursor composition or the size layer precursor composition). In some cases, heating may be useful to promote dissolution of the polyepoxide.

Examples of aromatic polyepoxides include polyglycidyl ethers of polyhydric phenols, such as bisphenol A diglycidyl ether (commonly referred to in the art as DGEBA) and Hexion Specialty Chemicals, Inc. of Columbus, Ohio Epon Resin 825, Epon Resin 828, Epon Resin 1001F, Epon Resin 1002F, Epon Resin 1004F, Epon Resin 1007F, and Epon Resin 1009F sold by Hexion Specialty Chemicals (e.g., Derived bisphenol A-derived and bisphenol F-derived epoxy resins having the trade designation "DER" (e.g., DER 332, available from Dow Chemical Company, Midland, Mich. DER 337, DER 362, and DER 364); Epoxy cresol-novolac resins; Epoxy phenol-novolac resins; And glycidyl esters of aromatic carboxylic acids (e.g., phthalic acid diglycidyl ester, isophthalic acid diglycidyl ester, trimellitic acid triglycidyl ester, and pyromellitic acid tetraglycidyl ester) And combinations thereof.

Examples of useful aliphatic polyepoxides include epoxycyclohexanecarboxylate (e.g., 3,4-epoxycyclohexylmethyl 3,4-epoxycyclohexanecarboxylate (e.g., ERL-4221 from Dow Chemical Company) Epoxy-2-methylcyclohexylmethyl 3,4-epoxy-2-methylcyclohexanecarboxylate; bis (3,4-epoxy-6-methylcyclohexylmethyl) adipate; 4-epoxy-6-methylcyclohexanecarboxylate (e. G., Available as ERL-4201 from Dow Chemical Company), vinylcyclohexene dioxide Bis (2,3-epoxycyclopentyl) ether (for example, available from Dow Chemical Company as ERL-0400), bis (3,4-epoxy- 6-methylcyclohexylmethyl) adipate (ERL-4269 from Dow Chemical Company); 2- (3,4-epoxycyclohexyl-5-ene) from Dow Chemical Company , 1'-spiro-3 ', 4'-epoxycyclohexane-1,3-dioxane, and 2,2-bis (3,4-epoxycyclohexyl) propane.

The amount of polyepoxide present in the make layer precursor is typically from about 40 to 70 wt%, preferably from 50 to 60 wt%, based on the total weight of solids (i.e., non-volatile components) in the make layer precursor Although amounts outside this range may also be used.

Useful multifunctional (meth) acrylates can be liquid or solid, but are typically liquids for ease of handling. Whether liquid or solid, the multifunctional (meth) acrylate should generally be selected to be soluble in the precursor composition. In some cases, heating may be useful in promoting the dissolution of multifunctional (meth) acrylates. Exemplary useful multifunctional (meth) acrylates include (meth) acrylate monomers, (meth) acrylate oligomers, (meth) acrylated polymers, and combinations thereof.

A wide variety of multifunctional (meth) acrylate (s) are commercially available from, for example, Sartomer Co., Exton, Pennsylvania, USA and UCB Chemicals Corp., Smyrna, Georgia, USA. ). ≪ / RTI >

Exemplary multifunctional (meth) acrylate (s) include but are not limited to ethylene glycol di (meth) acrylate, hexanediol di (meth) acrylate, triethylene glycol di (meth) acrylate and methacrylate, (Meth) acrylate, trimethylol propane tri (meth) acrylate and trimethacrylate, neopentyl glycol (meth) acrylate, glycerol tri (meth) acrylate, pentaerythritol tri (meth) acrylate and methacrylate, ethoxylated trimethylol propane tri Di (meth) acrylate and dimethacrylate, pentaerythritol tetra (meth) acrylate and tetramethacrylate, dipentaerythritol penta (meth) acrylate, sorbitol tri (meth) acrylate, sorbitol hexa ) Acrylate, bisphenol A di (meth) acrylate, ethoxylated bisphenol A di ) It includes the acrylate, and mixtures thereof.

Examples of useful multifunctional (meth) acrylate monomers include, for example, trimethylolpropane triacrylate, available as SR 351 from Sartomer Company; For example, ethoxylated trimethylolpropane triacrylate, available as SR 454 from Sartomer Company; For example, pentaerythritol tetraacrylate available as SR 295 from Sartomer Company; And neopentyl glycol diacrylate, available, for example, as SR 247 from Sartomer Company.

The polyfunctional acrylate may comprise one or more (meth) acrylate oligomers. Exemplary (meth) acrylate oligomers include (meth) acrylated epoxy oligomers such as bisphenol-A epoxy (meth) acrylate oligomers, aliphatic urethane (meth) acrylate oligomers, and aromatic urethane Oligomers. Additional useful multifunctional (meth) acrylate oligomers include, for example, polyethylene glycol 200 diacrylate available as SR 259 from Sartomer Corporation, and polyethylene glycol 400 diacrylate available as SR 344 from Satoromer Corporation Polyether oligomers; And acrylated epoxies including those available from Eucheby Chemical Industries, Inc., such as EBECRYL 3500, Ebecryl 3600, and Ebecryl 3700.

In some preferred embodiments, the multifunctional (meth) acrylate is present as a blend of polymerizable (meth) acrylates, or as a single component, having an average (meth) acryloxy group functionality of at least 2.2, at least 2.5, 3 or more.

The amount of polyfunctional (meth) acrylate (s) present in the make layer precursor is typically from about 5 to about 20 weight percent, based on the total weight of solids (i.e., non-volatile components) in the make layer precursor Is in the range of about 5 to about 15 wt%, and even more preferably about 8 to about 12 wt%, although amounts outside this range may also be used.

The make layer precursor and the size layer precursor may further comprise an optional 2 reactive polymeric component, for example, a compound having at least one free radically polymerizable group and at least one cationic polymerizable group. 2 reactive compound can be prepared, for example, by introducing one or more ethylenically unsaturated groups into a compound already containing at least one epoxy group or, conversely, by introducing one or more epoxy groups into a compound already containing at least one ethylenically unsaturated group .

Exemplary 2-reactive polymeric compounds include: 0.4 to 0.6 weight equivalents of acrylic acid and 1 mole of diglycidyl ether of bisphenol A, polyglycidyl ether of phenol-formaldehyde novolac, polyglycidyl ether of cresol-formaldehyde novolak poly Glycidyl ether, diglycidyl terephthalate, triglycidyl ester of trimellitic acid, dicyclopentadiene dioxide, vinylcyclohexene dioxide, bis (2,3-epoxycyclopentyl) ether, 3,4- Epoxycyclohexylmethyl 3,4-epoxycyclohexanecarboxylate, and bis (3,4-epoxy-6-methylcyclohexyl) methyl adipate.

When used, the optional two reactive materials are preferably selected so as not to significantly inhibit the curing of the cationically polymerizable resin. Exemplary groups that may interfere with such curing include primary, secondary and tertiary amines, amides, and imides.

The make layer precursor and the size layer precursor typically comprise a curing agent (e.g., a polyamine or a Lewis acid catalyst) for a polyepoxide curing agent and a free radical polymerization initiator (preferably a free radical photoinitiator) for polyfunctional (meth) ); ≪ / RTI > Depending on the curing conditions, this is not necessary.

Suitable curing agent (s) include those that are photosensitive and / or thermally sensitive, and preferably include one or more free radical polymerization initiators and one or more cationic polymerization catalysts, which may be the same or different. In order to minimize heating during curing while preserving the pot-life of the make layer precursor and / or the size layer precursor, the precursor is preferably photo-curable and comprises a photoinitiator and / or a photocatalyst.

As defined herein, a "photocatalyst" is a material that when exposed to actinic radiation forms an active species capable of at least partially polymerizing the polyepoxide used in the practice of the present invention. Optionally, the binder precursor may comprise at least one photocatalyst (e.g., an onium salt and / or a cationic organometallic salt).

Preferably, the onium salt photocatalyst comprises iodonium complex and / or sulphonium complex. Useful aromatic onium complexes are further described, for example, in U.S. Patent No. 4,256,828 (Smith). Exemplary aromatic iodonium complexes include diaryl iodonium hexafluorophosphate or diaryl iodonium hexafluoroantimonate. Exemplary aromatic sulfonium complex salts include triphenylsulfonium hexafluoroantimonate and p-phenyl (thiophenyl) diphenylsulfonium hexafluoroantimonate.

The aromatic onium salts useful in the practice of this invention are typically only photosensitive in the ultraviolet region of the spectrum; It can be sensitized to the near ultraviolet and visible lines of the spectrum by a sensitizer for known photolytic organic halogen compounds. Exemplary photosensitizers include aromatic amines and colored aromatic polycyclic hydrocarbons, for example, as described in U.S. Patent No. 4,250,053 (Smith).

Suitable photoactivatable organometallic complexes useful in the present invention include, for example, U.S. Pat. No. 5,059,701 (Keipert); 4,751,138 (Tumey); 4,985,340 (Palazzotto); 5,191,101 (Palazzo et al.); And 5,252,694 (Willett et al.).

Exemplary organometallic complex cations useful as photoactivatable catalysts include:

(? 6-benzene) (? 5-cyclopentadienyl) Fe ⁺ SbF ₆ ^- ,

(? 6-toluene) (? 5-cyclopentadienyl) Fe ⁺ SbF ₆ ^- ,

(? 6-xylene) (? 5-cyclopentadienyl) Fe ⁺ SbF ₆ ^- ,

(? 6-cumene) (? 5-cyclopentadienyl) Fe ⁺ PF ₆ ^- ,

(? 6-xylene (mixed isomer)) (? 5-cyclopentadienyl) Fe ⁺ SbF ₆ ^- ,

(eta 6-xylene (mixed isomer)) (? 5 -cyclopentadienyl) Fe ⁺ PF ₆ ^- ,

(? 6-o-xylene) (? 5-cyclopentadienyl) Fe ⁺ CF ₃ SO ₃ ^- ,

(? ⁶ -m-xylene) (? ⁵ -cyclopentadienyl) Fe ⁺ BF ₄ ^- ,

(η ⁶ - mesitylene) (η ⁵ - cyclopentadienyl) Fe ⁺ SbF ₆ ^- ,

(η ⁶ - hexamethylbenzene) (η ⁵ - the cyclopentadienyl carbonyl) Fe ⁺ SbF ₅ OH ^-, and

(η ⁶ - fluorene) (η ⁵ - cyclopentadienyl) Fe ⁺ SbF ₆ ^- .

Alternatively, the organometallic salt initiator may be accompanied by an accelerator such as an oxalate ester of a tertiary alcohol. If present, the promoter preferably comprises from about 0.1 to about 4 weight percent of the total binder precursor, more preferably about 60 weight percent of the organometallic salt initiator.

Useful commercially available photocatalysts include aromatic sulfonium complexes available from Dow Chemical Company under UVI-6974.

Useful free radical photoinitiators include, for example, those known to be useful for photocuring free-radically multifunctional acrylates. Exemplary photoinitiators include benzoin and derivatives thereof, for example, alpha -methylbenzoin; alpha-phenylbenzoin; ? -allylbenzoin; ? -benzylbenzoin; Benzoin ethers such as benzyl dimethyl ketal; Benzoin methyl ether; Benzoin ethyl ether; Benzoin n-butyl ether; Acetophenone and its derivatives such as 2-hydroxy-2-methyl-1-phenyl-1-propanone and 1-hydroxycyclohexyl phenyl ketone; 2-methyl-1- [4- (methylthio) phenyl] -2- (4-morpholinyl) -1-propanone; 2-Benzyl-2- (dimethylamino) -1- [4- (4-morpholinyl) phenyl] -1-butanone; Pivaloyl ethyl ether; Anhydrous ethyl ether; Anthraquinones, such as anthraquinones, such as 2-ethyl anthraquinone; 1-chloro anthraquinone; 1,4-dimethyl anthraquinone; 1-methoxyanthraquinone; Benzanthraquinonohalomethyltriazine; Benzophenone and derivatives thereof; Diaryl iodonium salts and triarylsulfonium salts; Titanium complexes such as bis (η ⁵ -2,4- cyclopentadienyl-1-yl) bis [2,6-difluoro -3- (1H- pyrrol-1-yl) phenyl] titanium, Halomethylnitrobenzene; Mono- and bis-acylphosphines; And combinations thereof.

The photoinitiators and photocatalysts useful in the present invention are generally from 0.01 to 10% by weight, based on the total solids of the make and size layer precursors, which is the amount of photocurable (i.e., crosslinkable by electromagnetic radiation) components of the binder precursor May typically be present in an effective amount ranging from 0.01 to 5, or even from 0.1 to 2% by weight, although amounts outside this range may also be useful.

Optionally, a thermosetting agent may be included in the binder precursor. Preferably, such a thermosetting agent is thermally stable at the temperature at which mixing of the components occurs. Exemplary thermosetting agents for epoxy resins and acrylates are well known in the art and are described, for example, in U.S. Patent No. 6,258,138 (DeVoe et al.). The heat curing agent may be present in the make layer precursor and / or the size layer precursor in any effective amount. Such amounts typically range from about 0.01 to 5 parts by weight, preferably from about 0.025 to 2 parts by weight, based on the total solids of the make and size / layer precursor, although amounts outside this range may also be useful.

The make layer precursor, the sizing layer precursor, and the optional super-sizing layer precursor used to make the flexible abrasive article according to the present invention may optionally be selected from, for example, phenolic resins (novolak or resole), aminoplasts, Cyanate resin, an isocyanate resin, and / or an alkyd resin.

In addition to the other components, the make, size and optional super-size layers of the flexible abrasive articles according to the present invention may contain optional additives, for example to modify performance and / or appearance . Exemplary optional additives include grinding aids, fillers, plasticizers, wetting agents, surfactants, pigments, coupling agents, fibers, lubricants, thixotropic materials, antistatic agents, suspending agents, pigments, and dyes.

Exemplary grinding aids, which may be organic or inorganic, include waxes, halogenated organic compounds, chlorinated waxes such as, for example, tetrachloronaphthalene, pentachloronaphthalene, and polyvinylchloride; Halide salts such as, for example, sodium chloride, potassium cryolite, sodium cryolite, ammonium cryolite, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluoride, potassium chloride, magnesium chloride; And metals and alloys thereof such as tin, lead, bismuth, cobalt, antimony, cadmium, iron, and titanium. Examples of other grinding aids include sulfur, organosulfur compounds, graphite, and metal sulfides. For example, a combination of different grinding aids may be used, as described in U.S. Patent No. 5,552,225 (Ho).

The basis weight of the make layer (i.e. after curing) may depend, for example, on the intended application (s), the type (s) of abrasive particles and the properties of the coated abrasive article being prepared, 1 to about 30 grams / square meter (i.e., gsm), preferably from about 10 to about 25 gsm, and more preferably from about 10 to about 20 gsm.

The make layer may be formed by coating the make layer precursor on the main surface of the backing. The make layer precursor may be applied by any known coating method such as, for example, applying a make layer to the backing, including, for example, roll coating, extrusion die coating, curtain coating, knife coating, gravure coating, Lt; / RTI >

After the make layer precursor is applied to the backing, but before the size layer precursor is applied, the abrasive particles may be applied to the make layer precursor, and then the make layer precursor may be selectively (e.g., in an a-step or b-step) Can be partially cured.

The abrasive particles suitable for use in the abrasive layer used in the practice of the present invention include any abrasive particles known in the abrasive art. Exemplary useful abrasive particles include, but are not limited to, molten aluminum oxide-based materials such as aluminum oxide, ceramic aluminum oxide (which may include one or more metal oxide modifiers and / or seeding or nucleating agents) Aluminum, silicon carbide, eutectic alumina-zirconia, diamond, ceria, titanium diboride, cubic boron nitride, boron carbide, garnet, flint, stonemason, sol-gel derived abrasive particles and blends thereof do. Preferably, the abrasive particles comprise molten aluminum oxide, heat-treated aluminum oxide, ceramic aluminum oxide, silicon carbide, alumina zirconia, garnet, diamond, cubic boron nitride, sol-gel derived abrasive particles, do. Examples of sol-gel abrasive particles include U.S. Pat. No. 4,314,827 (Leitheiser et al.); 4,518,397 (Raitai et al.); 4,623, 364 (Cottringer et al.); 4,744,802 (Schwabel); 4,770,671 (Monroe et al.); 4,881,951 (Wood et al.); 5,011,508 (Wald et al.); 5,090, 968 (Pellow); 5,139, 978 (Wood); 5,201,916 (Berg et al.); 5,227,104 (Bauer); 5,366, 523 (Rowenhorst et al.); 5,429,647 (Laramie); 5,498, 269 (Larmie); And 5,551,963 (Larmi).

The abrasive particles may be in the form of, for example, individual particles, agglomerates, abrasive composite particles, alpha alumina abrasive shards, and mixtures thereof. Exemplary agglomerates are described, for example, in U.S. Patent No. 4,652,275 (Bloecher et al.) And 4,799,939 (Bleuter et al). It is also within the scope of the present invention to use a diluent erodible agglomerate grain, for example, as described in U.S. Patent No. 5,078,753 (Broberg et al.). The abrasive composite particles include abrasive grains in the binder. Exemplary abrasive multiparticulates are described, for example, in U.S. Patent No. 5,549,962 (Holmes et al.). Alpha alumina abrasive shards are described in U.S. Patent Application Publication No. 2011/0314746 Al (Erickson et al.).

The abrasive particles typically have an average diameter of from about 0.1 to about 2000 micrometers, more preferably from about 1 to about 1300 micrometers. The abrasive particles are generally classified into a predetermined particle size distribution before use. Such a distribution typically has a particle size range from coarse to fine particles. In the abrasive field, this range is sometimes referred to as "coarse" fraction, "control" fraction, and "fine" fraction.

Abrasive particles classified according to the classification standards approved in the abrasive industry define the particle size distribution for each nominal grade within a numerical limit. Such an industry approved classification standard (ie, the nominal grade specified in the abrasive industry) includes the American National Standards Institute, Inc. (ANSI) standard, the Federation of European Producers of Abrasive Products (FEPA) Standard, and Japanese Industrial Standard (JIS) standards.

The ANSI rating designations (i.e., the nominal ratings specified) may be in ANSI 4, ANSI 6, ANSI 8, ANSI 16, ANSI 24, ANSI 36, ANSI 40, ANSI 50, ANSI 60, ANSI 80, ANSI 100, 150, ANSI 180, ANSI 220, ANSI 240, ANSI 280, ANSI 320, ANSI 360, ANSI 400, and ANSI 600. The FEPA class designations include P8, P12, P16, P24, P36, P40, P50, P60, P80, P100, P120, P150, P180, P220, P320, P400, P500, P600, P800, P1000 and P1200. The JIS class name is JIS8, JIS12, JIS16, JIS24, JIS36, JIS46, JIS54, JIS60, JIS80, JIS100, JIS150, JIS180, JIS220, JIS240, JIS280, JIS320, JIS360, JIS400, JIS600, JIS800, JIS1000, JIS1500, JIS2500, JIS4000, JIS6000, JIS8000 and JIS10,000. For use in manual sanding applications such as wood trim and molding (painted or unpainted) with shaped three-dimensional surfaces, the abrasive particles fall within the range of ANSI grades P100 to P320 (including endpoints) Size distribution.

Alternatively, the abrasive grains may be coated with a US Standard Test Sieve according to ASTM E-11 "Standard Specification for Wire Cloth and Sieves for Testing Purposes" Can be classified into a nominal screened grade. ASTM E-11 prohibits the requirements for the design and construction of test specimens using media of woven wire cloth mounted on the frame for the classification of materials according to the specified particle size. A typical designation may be represented as -18 + 20, which means that the abrasive grains pass through a specimen that meets the ASTM E-11 specification for the 18th sieve and a specimen that meets the ASTM E-11 specification for the 20th sieve ≪ / RTI > In some embodiments, the abrasive particles have a particle size such that most of the abrasive particles pass through an 18 mesh test body and can be retained on a 20, 25, 30, 35, 40, 45, or 50 mesh test body . In various embodiments of the present invention, the abrasive particles are: -18 + 20, -20 + 25, -25 + 30, -30 + 35, -35 + 40, -40 + 45, -45 + 60, -60 + 70, -70 + 80, -80 + 100, -100 + 120, -120 + 140, -140 + 170, -170 + 200, -200 + 230, -230 + 325, -325 + 400, -400 + 450, -450 + 500, or -500 + 635.

The coating weight for the abrasive particles may depend on, for example, the binder precursor used, the process for applying the abrasive particles, and the size of the abrasive particles, but is typically from about 5 to about 250 gsm (grams per square meter) , Preferably from 20 to 100 gsm, more preferably from 30 to 80 gsm, and more preferably from 45 to 65 gsm; However, other amounts may also be used.

The size layer precursor can then be applied over the make layer precursor and abrasive particles and the make and layer size precursors can be sufficiently cured to form a usable coated abrasive article. Curing can be accomplished using thermal and / or photochemical methods.

As with the make layer, the size layer may also be formed from the precursor composition (i.e., the size layer precursor). The sizing layer may comprise any of the components listed herein above for use in the make layer precursor.

The amount of polyepoxide present in the sizing layer precursor is typically from about 40 to 80 weight percent, preferably from 50 to 70 weight percent, based on the total weight of solids (i.e., non-volatile components) in the make layer precursor, And more preferably 55 to 65 wt%, although amounts outside this range may also be used.

The amount of polyfunctional (meth) acrylate (s) present in the sizing layer precursor is typically from about 5 to about 50 weight percent, based on the total weight of solids (i.e., non-volatile components) in the make layer precursor Is in the range of about 15 to about 40 wt%, and even more preferably about 25 to about 35 wt%, although amounts outside this range may also be used.

The basis weight of the size layer (i.e., after curing) will vary depending on the intended application (s), type (s) of abrasive particles, and properties of the coated abrasive article being made, but will generally range from 10 to 150 gsm , Preferably from 20 to 80 gsm, and more preferably from 35 to 55 gsm. The size layer is applied by any known coating method for applying, for example, a size layer to the backing, including, for example, roll coating, extrusion die coating, curtain coating, and spray coating.

Next, the sizing layer precursor and any uncured make layer precursors are fully cured to provide a usable coated abrasive article. Generally, this curing step involves thermal energy and / or radiation energy (e.g., ultraviolet and / or visible radiation or electron beam radiation), but this is not necessary. Useful forms of thermal energy include, for example, heat and infrared radiation. Exemplary sources of heat energy include ovens (e.g., a festoon oven), heating rolls, hot air blowers. Exemplary radiation energy sources include, for example, electron beams, ultraviolet light (e.g., a medium pressure mercury bulb, xenon flash lamp, or Type H or Type D microwave-driven bulb), and visible light. Other sources of radiation energy include infrared and microwave. Electron beam radiation, also known as ionizing radiation, may be used at a dose of about 0.1 to about 10 megares (Mrad), preferably about 1 to about 10 Mrad. Ultraviolet radiation refers to non-particulate radiation having a wavelength within a range of about 200 to about 400 nanometers (nm), preferably within a range of about 250 to 400 nm. In certain embodiments, ultraviolet radiation may be provided by ultraviolet light at a dose of 100 to 300 watts / cm. Visible radiation refers to non-particulate radiation having a wavelength within a range of about 400 to about 800 nm, and in some embodiments, within a range of about 400 to about 550 nm.

Optionally, a super-sizing layer may be applied to at least a portion of the size layer. When present, the super-size typically comprises a grinding aid and / or an anti-loading material. The optional super-sizing layer can serve to prevent or reduce the accumulation of swarf (abrasive material from the workpiece) between the abrasive particles, which can dramatically reduce the cutting ability of the coated abrasive article have. Useful supersize layers typically comprise a metal salt of a fatty acid (e.g., zinc stearate or calcium stearate), a salt of a phosphate ester (e.g., potassium tetrafluoroborate) Phosphate, ester, urea-formaldehyde resin, mineral oil, crosslinked silane, crosslinked silicone, and / or fluorine compound. Useful supersize materials are further described, for example, in U.S. Patent No. 5,556,437 (Lee et al.).

When present, the basis weight of the supersize layer may be from 1 to 50 gsm, more preferably from 5 to 30 gsm, and still more preferably from about 10 to about 20 gsm. The super-size may, for example, contain binders such as those used to make the sizing layer or make layer, but need not contain any binder resin. The super-sized layer is generally dried and / or cured to provide a flexible abrasive article, which may be, for example, a web-like sheet. Conversion to a particular shape (e.g., a rectangular sheet or disk) can be accomplished using conventional methods such as, for example, die cutting, knife cutting, and laser cutting.

The resulting flexible abrasive article may be further processed, for example, by printing, laser marking, trimming, punching, flexing, post-curing, Lt; / RTI >

In certain embodiments, e.g., where the flexible abrasive article is at least translucent, indicia or other marking may be placed on the first major surface of the backing (e.g., Printed, but may also be placed on the second major surface of the backing.

In some preferred embodiments, the various components are selected such that the flexible abrasive article is sufficiently translucent or transparent so that the workpiece can be visually perceived while the user polishes without removing the flexible abrasive article from the surface of the workpiece. This provides advantages over paper-backed abrasive products.

The flexible abrasive article according to the present invention is typically used in the production of painted or non-painted wood or metal workpieces (e.g., furniture and architectural trim, e.g., moldings), including especially curved and / , Hand rails, or cabinetry), for use in manual sanding applications. An advantage of a flexible abrasive product according to the present invention for this application is that it can be applied to a workpiece surface comprising an architectural trim with excellent hand feel, hand grip, translucent translucency, ≪ / RTI > flexibility and conformability.

In selected embodiments of the present invention

In a first embodiment, the present invention provides, as a flexible polished article,

Having an average thickness of from 4 to 6 mils (102 to 152 micrometers), a tensile strength of from 500 to 3200 psi (3.45 to 22.1 MPa), and a first major surface and a second major surface facing away from each other and comprising polyurethane And a single backing having an ultimate elongation of 230 to 530%; And

And an abrasive layer disposed on and fixed to the single backing,

The polishing layer

A makeup layer disposed on at least a portion of the first major surface of the single backing and comprising a polymerized reaction product of components comprising at least one polyepoxide and at least one multifunctional (meth) acrylate;

Abrasive particles fixed to the make layer; And

A make layer and at least a portion of the abrasive particles,

A size layer comprising a polymerized reaction product of components comprising at least one polyepoxide and at least one polyfunctional (meth) acrylate,

Wherein the second major surface of the single backing forms an outer major surface of the flexible abrasive article.

In a second embodiment, the present invention provides a flexible abrasive article according to the first embodiment, wherein said abrasive particles have a nominal size rating of ANSI grade P80 or less and ANSI grade P320 or more.

In a third embodiment, the present invention provides a flexible abrasive article according to the first embodiment, wherein said abrasive particles have a nominal size rating of ANSI grade P180 or lower and ANSI grade P320 or higher.

In a fourth embodiment, the present invention provides a flexible abrasive article according to any one of the first to third embodiments, wherein the average thickness of the backing is 4.5 to 5.5 mils.

In a fifth embodiment, the present invention provides a flexible polished article according to any one of the first to fourth embodiments, wherein the backing comprises thermoplastic polyurethane.

In the sixth embodiment, the present invention provides a flexible polished article according to any one of the first to fifth embodiments, wherein the above-described flexible polished article is translucent.

In a seventh embodiment, the present invention provides a flexible abrasive article according to any one of the first to sixth embodiments, further comprising a supersize layer disposed on at least a portion of the size layer .

In the eighth embodiment, the present invention is characterized in that the backing has a maximum tensile strength of 1000 to 2500 psi, and a maximum ultimate elongation of 300 to 460%. The flexible polishing according to any one of the first to seventh embodiments Provide the goods.

In the ninth embodiment, the present invention provides a flexible polishing member according to any one of the first to seventh embodiments, wherein the backing has a maximum tensile strength of 1600 to 2100 psi and a maximum ultimate elongation of 350 to 410% Provide the goods.

In a tenth embodiment, the present invention provides, as a flexible polishing article,

A single backing having a first major surface and a second major surface facing away from each other and comprising polyurethane and having an average thickness of 4 to 6 mils (102 to 152 micrometers); And

And an abrasive layer disposed on and fixed to the single backing,

The polishing layer

A makeup layer disposed on at least a portion of the first major surface of the single backing and comprising a polymerized reaction product of components comprising at least one polyepoxide and at least one multifunctional (meth) acrylate;

Abrasive particles fixed to the make layer; And

A make layer and a size layer disposed on at least a portion of the abrasive particles,

The sizing layer precursor comprises a polymerized reaction product of components comprising at least one polyepoxide and at least one multifunctional (meth) acrylate,

Wherein the second major surface of the single backing forms an outer major surface of the flexible abrasive article,

Wherein the flexible abrasive article has a tensile strength of 400 to 2400 psi (2.8 to 16.5 MPa) and an ultimate elongation of 180 to 380%.

In an eleventh aspect, the present invention provides a workpiece polishing method,

Providing a flexible abrasive article according to any one of the first to tenth embodiments;

Frictionally contacting at least a portion of the abrasive layer with the surface of the workpiece; And

Moving at least one of the surface of the polishing layer or the workpiece to polish the surface of the workpiece

A workpiece grinding method, and a workpiece grinding method.

In a twelfth embodiment, the present invention provides a method according to the tenth embodiment, wherein said workpiece comprises wood or metal painted or unpainted.

In a thirteenth embodiment, the present invention provides a method according to the eleventh or twelfth embodiment, wherein the workpiece comprises a building trim having three-dimensional detail.

In a fourteenth embodiment, the present invention provides a flexible abrasive article according to any one of the eleventh to thirteenth embodiments, wherein the flexible abrasive article is a hand-held type.

The objects and advantages of the present invention are further illustrated by the following non-limiting examples, but the specific materials and amounts thereof recited in these examples as well as other conditions and details are to be construed as unduly limiting the present invention .

Example

Unless otherwise stated, all parts, percentages, ratios, etc. in the examples and the remainder of this specification are by weight. Materials without sources are available, for example, from common commercial sources such as Aldrich Chemical Company, Milwaukee, Wisconsin, USA, or may be synthesized according to known methods.

The material abbreviations used in the examples

"ACR" refers to trimethylolpropane triacrylate.

"ABR" is a mixture of 96 wt.% Aluminum oxide, 3 wt.% Titanium dioxide, and less than 1 wt.%, Available as ARTIRUNDUM SFB from Art Abrasives Limited of Suzhou, Refers to a P320 semi-friable blend of mineral abrasive particles consisting of the entirety of the other oxides (silicon, magnesium, calcium, iron).

"AMOX" refers to di-t-amyl oxalate, which can be prepared by the esterification reaction of oxalic acid with t-amyl alcohol as described in Example 11 of U.S. Patent No. 4,904,814 (Frei et al. Quot;

"CHDM" refers to 1,4-cyclohexane dimethanol.

"EP1" is an epoxy equivalent weight of 525 to 550 g / equivalent, available from Epoxy 1001F from Momentum Specialty Chemicals, Inc. of Columbus, Ohio, having an average epoxy functionality of 2 Refers to a bisphenol-A epichlorohydrin epoxy resin.

"EP2" refers to a bisphenol-A epoxy resin, available as Epon 828 from Momentum Specialty Chemicals, Inc., having an epoxy equivalent weight of 185 to 192 g / equivalent and an average epoxy functionality of 2. [

"EP3" refers to (3 ', 4'-epoxycyclohexylmethyl) 3', 4'-epoxycyclohexanecarboxylate.

"PC1" is a copolymer of 4-thiophenylphenyldiphenylsulfonium hexafluoroantimonate in propylene carbonate and bis [4 (trifluoromethyl) phenyl) propionate obtained from Aceto Corporation of Fort Washington, - (diphenylsulfonio) phenyl] sulfide bis (hexafluoroantimonate).

"PC2" refers to 2,2-dimethoxy-2-phenylacetophenone, available from BASF of Ian Dot, Michigan, under the trade designation IRGACURE 651.

"PC3" refers to η ⁶ - [xylene (mixed isomer)] η ⁵ -cyclopentadienyl iron (1+) hexafluoroantimonate (1-).

"PC4" refers to 2,4,6-trimethylbenzoylphenylphosphinic acid ethyl ester obtained from BASF of Ian Dot, Michigan, USA under the trade name Irgacure TPO-L.

"PEP" is a high molecular weight, hydroxyl-terminated, saturated, linear, semicrystalline, copoly (co) polymer available from DINNAPOL S 1227 from Evonik Industries, Parsippany, Ester, M _w = 35,000 g / mole.

"PI" refers to 2-hydroxy-2-methyl-1-phenyl-1-propanone.

"Prop Carb " refers to propylene carbonate obtained from Huntsman Corp, Woodlands, Texas, under the trademark JEFFSOL PC.

"ZNST" refers to a 39 to 41 weight percent aqueous zinc stearate soap dispersion, obtained from eChem LTD, Leeds, UK, under the tradename EC994C.

Production of flexible film backing

A thermoplastic polyether polyurethane resin (available from Lubrizol Advanced Materials, Inc., Cleveland, Ohio, available as ESTAN 58887 NAT 021) was applied to an average film thickness of 5 mils And extruded. Representative tensile properties according to ASTM International Test Method D882-12 were as follows: down web = 131 ± 9 kg-force / cm 2 (1860 ± 130 psi, 12.8 ± 0.9 MPa) tensile strength and ultimate elongation = 391 ± 17%; Cross web = 126 ± 4 kg-force / cm 2 (1790 ± 60 psi, 12.3 ± 0.3 MPa) Tensile strength and ultimate elongation = 383 ± 18%.

Make  Preparation of layer precursors

According to the compositions listed in Table 1, a make resin was prepared as follows. AMOX, EP1, EP2, CHDM and PEP were directly metered into a twin screw extruder operating at 300 rpm with temperature zones of 30, 105, 110, 100, 65 and 60 캜. This mixed resin was then fed into a pin mixer operating at 1750 rpm, and ACR, PC2, PC3, PC4, and propcarb were metered directly into the pin mixer. The product from the pin mixer was fed to the heated coating die, at which time the flow rate from the pin mixer was controlled to achieve the make resin target on the abrasive backing.

[Table 1]

Preparation of Size Layer Precursor

Table 2 lists the components and amounts used to formulate the sizing resin. EP2, EP3, and ACR were mixed and mixed in a container to prepare a sizing resin. Prior to abrasive preparation, PC1 and PI were added to the premixed resin batch and stirred at room temperature for 30 minutes until homogeneous.

[Table 2]

Example 1

This example was prepared largely as follows. In a continuous process, the make layer (see Table 1 Formulation) precursor was coated onto the polyurethane flexible film with a nominal coating weight of 16.5 g / m ² . A polyethylene terephthalate liner was used to help transport the polyurethane film backing throughout the coating process and was later removed.

The coated web was then placed under a Fusion UV Systems equipped with a set of D-bulbs and a set of V-bulbs (both operating at 600 W / in (236 W / cm)) I passed it. Next, ABR abrasive grains were coated on the make layer with a nominal coating weight of 55 g / m < ² >, and then the web was heated for about 7 seconds at a nominal web temperature setting of 100 DEG C under an infrared heater. Next, a size layer precursor (see Formulation 2) was coated on the make layer and the abrasive particles with a nominal dry coat weight of 43 g / m < ² >, and a set of H-bulbs and two sets of D-bulbs 600 W / in (236 W / cm)). This was then treated by passing it through an infrared oven having a target outlet web temperature of 125 캜. The ZNST was then coated onto the size layer with a nominal coating weight of 14 g / m < ² > and processed by passing it through a drying oven having a target exit web temperature of 135 [deg.] C. The resulting coated abrasive article was then held at room temperature (i.e., 20 to 24 ° C) and 40 to 60% relative humidity until tested.

Comparative Example A

An aluminum oxide sand (220 grit, paper-backed) available from 3M Company was used as Comparative Example A (CE-A).

Backing wear evaluation test

(6.4 cm x 15.2 cm, "short" specimen) and 2.5 inches x 9 inches (6.4 cm x 15.2 cm) from the coated abrasive article to be evaluated (i.e., sandpaper CE- A or the flexible abrasive article according to example 1) (9.4 cm x 22.9 cm, "long" specimen).

The test apparatus consisted of a rubber bottomed sanding block with a mechanically driven rubber floor on which a sample was mounted (the surface area of the floor was 2.5 inches by 6.0 inches (6.4 cm by 15.2 cm)).

Adhesive transfer tape (# 950 available from 3M Company) was applied to the grit side of the short specimen. The liner was removed and a double-sided adhesive tape (# 442 KW available from 3M Company) was applied over the transfer tape adhesive. The liner was removed from the double-sided tape and a sample was attached to the rubber bottom of the sanding block fixture. The long specimens were then attached onto a short specimen (with the grit face down) and secured with a clip on each end of the sanding block fixture.

The grit face of the long specimen was pressed against the stationary surface of the cellulose acetabutyl butyrate base with a constant load of 16 pounds (7.3 kg) and the 18 inch (46 cm) width (Y direction) x 24 inch (61 cm) length X direction) was passed back and forth at a speed of 20 inches (51 cm) per second in the X direction and 3 inches (7.6 cm) per second in the Y direction. The backing surfaces of short specimens and long specimens rubbed against each other during testing. One pass was considered one pass back and forth, and there were 50 passes per cycle. This was repeated until the sample backing was torn. The number of cycles taken to tear the sample was recorded.

Backing wear evaluation test data

Backing Wear As noted in the evaluation test, the flexible abrasive article of Example 1 was evaluated for backing wear compared to CE-A. Three samples of CE-A were tested. The maximum number of cycles for which the CE-A specimen was sustained was 44 cycles. Six samples of the flexible abrasive article of Example 1 were tested. All six reached 700 cycles without tearing and the test was stopped at that time.

All cited references, patents, and patent applications cited in this patent application are incorporated herein by reference in their entirety in a consistent manner. In the event of discrepancies or inconsistencies between the included references and portions of the present application, the information in the foregoing description will prevail. The foregoing description, given to enable those skilled in the art to practice the claimed invention, should not be construed as limiting the scope of the invention as defined by the claims and all equivalents thereto.

Claims (14)

As a flexible polishing article,
Having an average thickness of from 4 to 6 mils, a tensile strength of from 500 to 3200 psi, and a tensile strength of from 230 to 530%, of a first major surface and a second major surface facing away from each other, Unitary backing with ultimate elongation; And
And an abrasive layer disposed on and fixed to the single backing,
The polishing layer
A make layer comprising a polymerized reaction product of components comprising at least one polyepoxide and at least one polyfunctional (meth) acrylate, disposed on at least a portion of the first major surface of the single backing, );
Abrasive particles fixed to the make layer; And
A make layer and a size layer disposed on at least a portion of the abrasive particles,
The size layer precursor comprises a polymerized reaction product of components comprising at least one polyepoxide and at least one multifunctional (meth) acrylate,
Wherein the second major surface of the single backing forms an outer major surface of the flexible abrasive article. The abrasive article of claim 1, wherein the abrasive particles have a nominal size grade of ANSI grade P80 or less or ANSI grade P320 or more. 2. The abrasive article of claim 1, wherein the abrasive particles have a nominal size rating of ANSI grade P180 or less or ANSI grade P320 or more. 4. A flexible abrasive article according to any one of claims 1 to 3, wherein the average thickness of the backing is 4.5 to 5.5 mils. 5. A flexible abrasive article according to any one of claims 1 to 4, wherein the backing comprises a thermoplastic polyurethane. The flexible polishing article according to any one of claims 1 to 5, wherein the flexible polishing article is translucent. 7. The article of any one of claims 1 to 6, further comprising a supersize layer disposed on at least a portion of the size layer. 8. A flexible abrasive article according to any one of claims 1 to 7, wherein the backing has a maximum tensile strength of 1000 to 2500 psi and a maximum ultimate elongation of 300 to 460%. 8. A flexible abrasive article according to any one of claims 1 to 7, wherein the backing has a maximum tensile strength of 1600 to 2100 psi and a maximum ultimate elongation of 350 to 410%. As a flexible polishing article,
A single backing having a first major surface and a second major surface facing away from each other, comprising a polyurethane and having an average thickness of from 4 to 6 mils; And
And an abrasive layer disposed on and fixed to the single backing,
The polishing layer
A makeup layer disposed on at least a portion of the first major surface of the single backing and comprising a polymerized reaction product of components comprising at least one polyepoxide and at least one multifunctional (meth) acrylate;
Abrasive particles fixed to the make layer; And
A make layer and a size layer disposed on at least a portion of the abrasive particles,
The sizing layer precursor comprises a polymerized reaction product of components comprising at least one polyepoxide and at least one multifunctional (meth) acrylate,
Wherein the second major surface of the single backing forms an outer major surface of the flexible abrasive article,
Wherein the flexible abrasive article has a tensile strength of 400 to 2400 psi (2.8 to 16.5 MPa) and an ultimate elongation of 180 to 380%. As a workpiece polishing method,
Providing a flexible abrasive article according to any one of claims 1 to 10;
Frictionally contacting at least a portion of the abrasive layer with the surface of the workpiece; And
Moving at least one of the surface of the polishing layer or the workpiece to polish the surface of the workpiece
And grinding the workpiece. 12. The method of claim 11, wherein the workpiece comprises painted or unpainted wood or metal. 14. The method of claim 11 or 12, wherein the workpiece comprises a trim for construction with three-dimensional detail. 14. The method according to any one of claims 11 to 13, wherein the flexible abrasive article is a hand-held type.

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