WO1996005022A1 - Article abrasif - Google Patents
Article abrasif Download PDFInfo
- Publication number
- WO1996005022A1 WO1996005022A1 PCT/US1995/009316 US9509316W WO9605022A1 WO 1996005022 A1 WO1996005022 A1 WO 1996005022A1 US 9509316 W US9509316 W US 9509316W WO 9605022 A1 WO9605022 A1 WO 9605022A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- abrasive article
- adhesive
- substrate
- abrasive
- hot melt
- Prior art date
Links
- 239000002245 particle Substances 0.000 claims abstract description 47
- 239000000758 substrate Substances 0.000 claims abstract description 37
- 239000004831 Hot glue Substances 0.000 claims abstract description 33
- 238000000034 method Methods 0.000 claims abstract description 25
- 125000003808 silyl group Chemical group [H][Si]([H])([H])[*] 0.000 claims abstract description 16
- 239000012790 adhesive layer Substances 0.000 claims abstract description 11
- 229920000642 polymer Polymers 0.000 claims abstract description 9
- 238000000151 deposition Methods 0.000 claims abstract 3
- 238000000576 coating method Methods 0.000 claims description 38
- 230000001070 adhesive effect Effects 0.000 claims description 37
- 239000000853 adhesive Substances 0.000 claims description 36
- 239000011248 coating agent Substances 0.000 claims description 34
- 239000010410 layer Substances 0.000 claims description 26
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 20
- 239000000203 mixture Substances 0.000 claims description 15
- 239000003054 catalyst Substances 0.000 claims description 14
- 229920005989 resin Polymers 0.000 claims description 12
- 239000011347 resin Substances 0.000 claims description 12
- 239000006260 foam Substances 0.000 claims description 10
- 239000000123 paper Substances 0.000 claims description 10
- 239000007787 solid Substances 0.000 claims description 10
- 239000011230 binding agent Substances 0.000 claims description 8
- -1 cycloalkyi Chemical group 0.000 claims description 8
- 230000007062 hydrolysis Effects 0.000 claims description 6
- 238000006460 hydrolysis reaction Methods 0.000 claims description 6
- 229920002635 polyurethane Polymers 0.000 claims description 6
- 239000004814 polyurethane Substances 0.000 claims description 6
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 claims description 5
- 238000001125 extrusion Methods 0.000 claims description 5
- 229920001568 phenolic resin Polymers 0.000 claims description 5
- 229910000077 silane Inorganic materials 0.000 claims description 5
- 229920001807 Urea-formaldehyde Polymers 0.000 claims description 4
- DQXBYHZEEUGOBF-UHFFFAOYSA-N but-3-enoic acid;ethene Chemical compound C=C.OC(=O)CC=C DQXBYHZEEUGOBF-UHFFFAOYSA-N 0.000 claims description 4
- 239000005038 ethylene vinyl acetate Substances 0.000 claims description 4
- 239000004745 nonwoven fabric Substances 0.000 claims description 4
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 claims description 4
- ODGAOXROABLFNM-UHFFFAOYSA-N polynoxylin Chemical compound O=C.NC(N)=O ODGAOXROABLFNM-UHFFFAOYSA-N 0.000 claims description 4
- 239000002759 woven fabric Substances 0.000 claims description 4
- 229920000877 Melamine resin Polymers 0.000 claims description 3
- 239000004952 Polyamide Substances 0.000 claims description 3
- 239000004698 Polyethylene Substances 0.000 claims description 3
- UKLDJPRMSDWDSL-UHFFFAOYSA-L [dibutyl(dodecanoyloxy)stannyl] dodecanoate Chemical group CCCCCCCCCCCC(=O)O[Sn](CCCC)(CCCC)OC(=O)CCCCCCCCCCC UKLDJPRMSDWDSL-UHFFFAOYSA-L 0.000 claims description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 3
- 229920005822 acrylic binder Polymers 0.000 claims description 3
- 125000000217 alkyl group Chemical group 0.000 claims description 3
- 230000000903 blocking effect Effects 0.000 claims description 3
- 229920003023 plastic Polymers 0.000 claims description 3
- 239000004033 plastic Substances 0.000 claims description 3
- 229920002647 polyamide Polymers 0.000 claims description 3
- 229920000573 polyethylene Polymers 0.000 claims description 3
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 2
- 150000001252 acrylic acid derivatives Chemical class 0.000 claims description 2
- 125000002947 alkylene group Chemical group 0.000 claims description 2
- 125000005529 alkyleneoxy group Chemical group 0.000 claims description 2
- 125000003118 aryl group Chemical group 0.000 claims description 2
- YHWCPXVTRSHPNY-UHFFFAOYSA-N butan-1-olate;titanium(4+) Chemical compound [Ti+4].CCCC[O-].CCCC[O-].CCCC[O-].CCCC[O-] YHWCPXVTRSHPNY-UHFFFAOYSA-N 0.000 claims description 2
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 claims description 2
- 239000008116 calcium stearate Substances 0.000 claims description 2
- 235000013539 calcium stearate Nutrition 0.000 claims description 2
- 150000001875 compounds Chemical class 0.000 claims description 2
- 239000000835 fiber Substances 0.000 claims description 2
- 125000005843 halogen group Chemical group 0.000 claims description 2
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims description 2
- 239000004711 α-olefin Substances 0.000 claims description 2
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims 2
- 239000002585 base Substances 0.000 claims 2
- 229920006332 epoxy adhesive Polymers 0.000 claims 2
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 claims 2
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims 1
- 229910052791 calcium Inorganic materials 0.000 claims 1
- 239000011575 calcium Substances 0.000 claims 1
- 229910052736 halogen Inorganic materials 0.000 claims 1
- 239000012943 hotmelt Substances 0.000 description 14
- 239000000463 material Substances 0.000 description 12
- 238000001723 curing Methods 0.000 description 8
- 238000009472 formulation Methods 0.000 description 7
- 239000002904 solvent Substances 0.000 description 7
- 239000003082 abrasive agent Substances 0.000 description 6
- 238000006243 chemical reaction Methods 0.000 description 6
- 238000001035 drying Methods 0.000 description 6
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 5
- 230000037452 priming Effects 0.000 description 5
- 239000004923 Acrylic lacquer Substances 0.000 description 4
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- 229920001971 elastomer Polymers 0.000 description 3
- 239000012948 isocyanate Substances 0.000 description 3
- 150000002513 isocyanates Chemical class 0.000 description 3
- 238000011068 loading method Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 238000005065 mining Methods 0.000 description 3
- 238000013008 moisture curing Methods 0.000 description 3
- 238000002360 preparation method Methods 0.000 description 3
- 239000005060 rubber Substances 0.000 description 3
- 238000005507 spraying Methods 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- OGSPWJRAVKPPFI-UHFFFAOYSA-N Alendronic Acid Chemical compound NCCCC(O)(P(O)(O)=O)P(O)(O)=O OGSPWJRAVKPPFI-UHFFFAOYSA-N 0.000 description 2
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 2
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 239000003963 antioxidant agent Substances 0.000 description 2
- 230000003078 antioxidant effect Effects 0.000 description 2
- 239000004202 carbamide Substances 0.000 description 2
- 125000004432 carbon atom Chemical group C* 0.000 description 2
- 238000007796 conventional method Methods 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 229920001577 copolymer Polymers 0.000 description 2
- 239000010432 diamond Substances 0.000 description 2
- 229910003460 diamond Inorganic materials 0.000 description 2
- 239000012975 dibutyltin dilaurate Substances 0.000 description 2
- 238000007607 die coating method Methods 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 229910052500 inorganic mineral Inorganic materials 0.000 description 2
- 230000003993 interaction Effects 0.000 description 2
- IQPQWNKOIGAROB-UHFFFAOYSA-N isocyanate group Chemical group [N-]=C=O IQPQWNKOIGAROB-UHFFFAOYSA-N 0.000 description 2
- 239000011707 mineral Substances 0.000 description 2
- 239000000178 monomer Substances 0.000 description 2
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 2
- 239000002985 plastic film Substances 0.000 description 2
- 229920006255 plastic film Polymers 0.000 description 2
- 150000003254 radicals Chemical class 0.000 description 2
- 229910003466 silicon carbide mineral Inorganic materials 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- ZNRLMGFXSPUZNR-UHFFFAOYSA-N 2,2,4-trimethyl-1h-quinoline Chemical compound C1=CC=C2C(C)=CC(C)(C)NC2=C1 ZNRLMGFXSPUZNR-UHFFFAOYSA-N 0.000 description 1
- XMNIXWIUMCBBBL-UHFFFAOYSA-N 2-(2-phenylpropan-2-ylperoxy)propan-2-ylbenzene Chemical compound C=1C=CC=CC=1C(C)(C)OOC(C)(C)C1=CC=CC=C1 XMNIXWIUMCBBBL-UHFFFAOYSA-N 0.000 description 1
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- 229910052580 B4C Inorganic materials 0.000 description 1
- 229910052582 BN Inorganic materials 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
- OWYWGLHRNBIFJP-UHFFFAOYSA-N Ipazine Chemical compound CCN(CC)C1=NC(Cl)=NC(NC(C)C)=N1 OWYWGLHRNBIFJP-UHFFFAOYSA-N 0.000 description 1
- 229920002633 Kraton (polymer) Polymers 0.000 description 1
- 239000004594 Masterbatch (MB) Substances 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- BGYHLZZASRKEJE-UHFFFAOYSA-N [3-[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxy]-2,2-bis[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxymethyl]propyl] 3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoate Chemical compound CC(C)(C)C1=C(O)C(C(C)(C)C)=CC(CCC(=O)OCC(COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)(COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)=C1 BGYHLZZASRKEJE-UHFFFAOYSA-N 0.000 description 1
- 239000006061 abrasive grain Substances 0.000 description 1
- 125000004183 alkoxy alkyl group Chemical group 0.000 description 1
- 125000003277 amino group Chemical group 0.000 description 1
- 239000002216 antistatic agent Substances 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 229920001400 block copolymer Polymers 0.000 description 1
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 229910000420 cerium oxide Inorganic materials 0.000 description 1
- 239000011045 chalcedony Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000000460 chlorine Substances 0.000 description 1
- 229910052801 chlorine Inorganic materials 0.000 description 1
- 238000007334 copolymerization reaction Methods 0.000 description 1
- 239000010431 corundum Substances 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000001548 drop coating Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000009503 electrostatic coating Methods 0.000 description 1
- 229910001651 emery Inorganic materials 0.000 description 1
- NKSJNEHGWDZZQF-UHFFFAOYSA-N ethenyl(trimethoxy)silane Chemical compound CO[Si](OC)(OC)C=C NKSJNEHGWDZZQF-UHFFFAOYSA-N 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 239000010433 feldspar Substances 0.000 description 1
- IVJISJACKSSFGE-UHFFFAOYSA-N formaldehyde;1,3,5-triazine-2,4,6-triamine Chemical compound O=C.NC1=NC(N)=NC(N)=N1 IVJISJACKSSFGE-UHFFFAOYSA-N 0.000 description 1
- SLGWESQGEUXWJQ-UHFFFAOYSA-N formaldehyde;phenol Chemical compound O=C.OC1=CC=CC=C1 SLGWESQGEUXWJQ-UHFFFAOYSA-N 0.000 description 1
- 239000002223 garnet Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 238000009499 grossing Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 1
- 235000013980 iron oxide Nutrition 0.000 description 1
- VBMVTYDPPZVILR-UHFFFAOYSA-N iron(2+);oxygen(2-) Chemical class [O-2].[Fe+2] VBMVTYDPPZVILR-UHFFFAOYSA-N 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- NFFIWVVINABMKP-UHFFFAOYSA-N methylidynetantalum Chemical compound [Ta]#C NFFIWVVINABMKP-UHFFFAOYSA-N 0.000 description 1
- 239000012768 molten material Substances 0.000 description 1
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 description 1
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229920001083 polybutene Polymers 0.000 description 1
- 229920006267 polyester film Polymers 0.000 description 1
- 239000011527 polyurethane coating Substances 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000008262 pumice Substances 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 239000011044 quartzite Substances 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 238000007761 roller coating Methods 0.000 description 1
- 125000005372 silanol group Chemical group 0.000 description 1
- 239000000741 silica gel Substances 0.000 description 1
- 229910002027 silica gel Inorganic materials 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 238000010561 standard procedure Methods 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 229920006132 styrene block copolymer Polymers 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 229910003468 tantalcarbide Inorganic materials 0.000 description 1
- XOLBLPGZBRYERU-UHFFFAOYSA-N tin dioxide Chemical compound O=[Sn]=O XOLBLPGZBRYERU-UHFFFAOYSA-N 0.000 description 1
- 229910001887 tin oxide Inorganic materials 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 238000011282 treatment Methods 0.000 description 1
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
- B24D3/20—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially organic
- B24D3/28—Resins or natural or synthetic macromolecular compounds
Definitions
- This invention relates to an abrasive article comprising a cured hot melt adhesive and to a method of preparation.
- Abrasive products are normally prepared by coating one surface of a substrate with a first binder layer having adhesive properties, often referred to in the art as the "make”. Particles of abrasive material are applied to the coated substrate and partially embedded therein. A layer of a second binder, often referred to as the "size”, is then applied to the material. The thickness of the second binder layer regulates the amount of the abrasive material extending above the binder medium. Anti-loading or anti-static materials having generally been included in a further optional layer, referred to in the art as the "supersize".
- the adhesives used to form the make are generally water- or solvent-based and include phenolic resins, urea-formaldehyde, melamine- formaldehyde and combinations thereof. Other adhesive which have been used are based on animal hide glue and starch. Similar adhesives have been used for the size.
- the hot melt adhesive is used at 100% solids content and by suitable selection of the application temperature will maintain the desired orientation of the abrasive particles.
- the hot melt adhesive is compatible with many size formulations and allows the application of water-based size over the make and abrasive particles, the moisture content of the size participating in the curing of the make adhesive ensuring strong bonding between the make and the size.
- Other sizes may be employed, e.g., hot melt or solvent-based formulations, and may be applied before or after curing the make adhesive coating.
- Hot melt adhesives are 100% solid polymeric materials which form bonds on cooling. They are generally composed of a combination of resins, waxes and stabilizers. Coating is normally by die coating or extrusion, but can also be by spray coating. Moisture-cured polyurethane coatings comprise isocyanate-terminated prepolymers which, after application, are cured by reaction of the residual isocyanate groups with moisture. The amino groups initially formed react with more isocyanate groups to form urea linkages.
- the moisture curing hot melt polyurethane may be applied to any substrate which will withstand the application temperature of the adhesive.
- the HMPU may be coated directly on the substrate or a priming or presize layer may be applied prior to its application.
- These priming or presize layers may be solvent-based, water-based or hot melt.
- the priming or presize layer is conveniently hot melt since it may readily be applied at the same coating station as the HMPU make.
- Priming or presize layers are particularly useful on substrates which have rough surfaces or surfaces with voids e.g., open-cell foams, and woven and non- woven fabrics, since it assists in smoothing the surface and reduces the amount of HMPU required for the make, which tends to be a more expensive component than the presize material.
- Priming or presize layers are not normally required on closed-cell foams and other substrates having a substantially sealed surface.
- Moisture-curing hot melt adhesives in which the cure involves interactions of silyl groups are known in the literature, and some are available commercially. Such materials can be totally free of isocyanates, as described in GB 2237022, WO 92/05226, GB 2197326, EP 0202491 , US 4,960,844 and Japanese Published Application Nos. 4-202585, 4-1 14078. and 3-149277. Moisture-curing hot melts containing both isocyanate and silyl groups have also been disclosed.
- the present invention utilizes alternative hot melt adhesives not requiring the use of isocyanates in the preparation of abrasive elements.
- One aspect of the present invention relates to an abrasive article comprising a substrate comprising a first major surface, an adhesive layer on said first major surface of said substrate; said adhesive layer comprising a hot melt adhesive comprising a polymer cross-linked via hydrolyzed or condensed silyl groups and abrasive particles adhered therein.
- the adhesive used in the present invention is a 100% solids resinous formulation which melts to a fluid state at elevated temperatures (e.g., in the range 50 to 200°C).
- the adhesive may be coated on a substrate by conventional techniques such as extrusion, die coating, spraying etc.
- the adhesive solidifies and further cures to a cross-linked three-dimensional network via the mutual interaction of silyl groups incorporated in the resin, the curing reaction being activated by moisture.
- Abrasive articles of the invention may be manufactured by coating a surface of a suitable substrate with the hot melt adhesive as described above, and applying abrasive particles to the molten or semi-molten adhesive coating so that they become adhered therein.
- the application of abrasive particles may be, for example, by drop coating or electrostatically coating the particles, both of which are standard techniques in the abrasives industry.
- the thickness of the adhesive coating and the dimensions of the particles are preferably such that most if not all of the particles partially project above the surface of the coating. As the adhesive cools, it solidifies completely and cures to a three-dimensional network, and hence bonds the particles firmly to the substrate.
- the substrate may comprise any of the materials commonly used as the backing for coated abrasive articles, including paper, cloth, plastic films, plastic fibers, fibrous bases, woven and nonwoven webs/fabrics, foams, foamed polymeric materials, and laminates etc.
- the substrate as described above, optionally may be precoated with a suitable resin ("pre- sized") in order to seal the surface, for example, or otherwise modify its surface properties.
- pre-sized may be beneficial in the case of porous materials and/or irregular surfaces, as in open cell foams, nonwoven webs etc.
- Suitable presizes may be applied as solvent- or water-based formulations, or as 100% solids hot melt formulations.
- Hot melt formulations are preferred and examples include a hot melt ethylene vinyl acetate commercially available from Evode, Stafford, Staffordshire, United Kingdom, under the trade designation "Thermaflow 6876"; a hot melt polyethylene commercially available from Minnesota Mining and Manufacturing Company, St. Paul, MN, under the trade designation "3748”; a hot melt polyamide commercially available from Minnesota Mining and Manufacturing Company, St. Paul, MN, under the trade designation "3789".
- a pre-formed plastic film may be applied to the substrate, which is a useful option where the substrate is an open cell foam, or a woven or non-woven fabric.
- the abrasive article may additionally comprise a size layer.
- the size layer may comprise any of the materials conventionally used, but preferably comprises a thermosetting resin (e.g., phenol-formaldehyde or urea-formaldehyde) in the form of an aqueous solution or dispersion, coated and cured according to conventional techniques.
- a thermosetting resin e.g., phenol-formaldehyde or urea-formaldehyde
- the water from such a coating serves to activate the curing reaction in the adhesive layer, while the thermosetting resin provides additional strength and controls the degree to which the abrasive particles project above the surface.
- Suitable size materials include a water-based acrylic commercially available from Evode, Stafford, Staffordshire, United Kingdom, under the trade designation "DP-90-4101"; water-based polyurethanes commercially available from Baxenden, Droitwich, Worcestshire, United Kingdom, under the trade designation "Witcobond 732", “Witcobond 769” and “Witcobond 788".
- Other sizes may be employed, e.g., hot melt or solvent-based formulations, which may be applied before or after curing the make adhesive coating.
- Additives such as anti-loading treatments, static control agents, etc., may be included in the size layer, or coated in a separate (supersize) layer, in accordance with known techniques.
- the abrasive articles may also comprise a supersize, preferably antiloading supersize of the type disclosed in U.S. Patent No. 5,164,265 and its equivalent, EP-0433031.
- Particularly preferred supersize compositions comprise calcium stearate and a fluorinated additive, e.g., a fluorinated additive commercially available from Minnesota Mining and Manufacturing Company, St. Paul, MN, under the trade designation "FC396", in a water-based acrylic binder, e.g., a water-based acrylic binder commercially available from Vinamul, Carshalton, Surrey, United Kingdom, under the trade designation "Vinacryl".
- the hot melt adhesives useful in the invention comprise a cross- linkable polymer having silyl groups represented by the formula:
- A represents a divalent organic radical, preferably an optionally substituted alkylene, alkyleneoxy, alkylene-phenylene, or alkylene-oxy- alkylene chain;
- X represents a leaving group displaceable by hydrolysis, preferably a halogen atom, e.g., chlorine, or a group R 1 0 or R 1 COO in which R 1 is a C ⁇ - ⁇ o, preferably alkyl or alkoxyalkyl group; m is 1 , 2, or 3, preferably 2 or 3; and
- R represents a blocking group not displaceable by hydrolysis, for example, a C 1 - alkyl group, a cycloalkyi of up to 8 carbon atoms, or an aryl group of up to 10 carbon atoms.
- silyl groups are readily hydrolyzed by moisture (from the atmosphere or externally supplied) to from silanol groups Si - OH, which condense with one another to form -Si-O-Si- linkages as disclosed, for example, in WO 92/05226, corresponding to U.S. Patent Nos. 5,227,442; 5,296,561 ; and 5,397,648.
- the silyl groups are covalently bonded to one or more of the resin(s) constituting the hot melt adhesive.
- silyl groups are attached to about 0.1 to 20.0 mol% of the repeating units, more commonly about 0.3 to 5.0 mol%.
- the remaining repeating units may be derived from any of variety of monomers, such as alpha-olefins, acrylates and other vinyl compounds, as described in the prior art.
- the hot melt adhesive may comprise additional resins, especially tackifying resins, in order to adjust the physical properties such as melt viscosity.
- the adhesive may also comprise a catalyst for the curing reaction, the preferred catalyst being an organotin compound or a titanate, such as dibutyltindilaurate or tetrabutyltitanate. Typical catalyst loadings are in the range 0.1 to 2.5% by weight based on the weight of total solids. In embodiments of the invention comprising an aqueous size coating, a catalyst may be unnecessary.
- Hot melt adhesives containing a cure catalyst optionally may be used in two-part form, with the catalyst and silane-functional resin supplied separately and mixed immediately prior to coating or during the coating process e.g., by extrusion through adjacent dies.
- a commercially available hot melt adhesive suitable for use in the invention was supplied by Swift Adhesives Ltd., Twickenham, United Kingdom, under the trade designation "X200/9".
- One method for preparing this adhesive is believed to be as follows: combining a silane grafted copolymer in an amount of about 15 parts by weight; a hydrogenated alicylic hydrocarbon-solid midblock compatible tackifying resin available from Exxon Chemical Company, Houston, TX, under the trade designation "Escorez 5380" in an amount of about 40 parts by weight; polybutene - liquid mid-block compatible plasticizer available from BP Chemicals, Cleveland, OH, under the trade designation "Hyvis 30" in an amount of about 45 parts by weight; a catalyst masterbatch (1% by weight dibutyl tin dilaurate in ethylene vinyl acetate) in an amount of about 1.7 parts by weight; and an antioxidant available from Ciba Geigy, Ardsley, NY, under the trade designation "Irganox 1010" in an amount of
- the silane grafted copolymer (i.e., a silane grafted styrene ABA block copolymer) can be prepared as follows: 100 parts by weight of a styrene-ethylene-butylene-styrene block copolymer available from Shell Chemical Company, Houston, TX, under the trade designation "Kraton G1652" can be reacted with two parts by weight of vinyl trimethoxy silane using 0.17 parts by weight of dicumyl peroxide as a free radical generator and 0.5 parts by weight of an antioxidant available under the trade designation "Flectol H,” from Monsanto.
- the reaction can be carried out in a PR46 Buss Ko-Kneader with the heater units set at 200°C/240°C/160°C and the die heater at setting number 7.
- the material produced can be face cut and air cooled at an output rate of 5.2 kg per hour.
- the composition can be homogenized prior to the addition of the catalyst.
- the catalyst can then be mixed in and the composition can be filled into a container for a hot melt adhesive applicator.
- a silica gel sachet may be placed in the filled container before it is sealed. This preparation is essentially as described in Example 3 of GB 2237022.
- hot melt adhesive used in a given application will be selected according to the particular requirements.
- hot melt adhesives having viscosities in the range 3,000 to 12,000 mPa.s
- the make coating is generally applied by heating the hot melt adhesive to a temperature at which the viscosity is suitable for coating and applying the molten material to the substrate by an extrusion die, or optionally two adjacent dies in the case of two-part composition. Coating temperatures depend upon the particular adhesive, but are generally in the range 50 to 200°C, usually in the range 120° to 160°C.
- the coating weight depends upon the surface of the substrate, the presence or absence of a presize, and the size of the abrasive particles. Coating weights are generally within the range 1 to 250 g/m 2 , the lower end of the range being applicable to smooth substrates e.g., paper, and to the use of fine grade abrasive particles. Hot melt size and presize coatings may be applied in a similar manner to the make coating.
- the abrasive particles are generally applied to the coated substrate immediately after application of the adhesive e.g., by passing the substrate through a curtain of abrasive particles or by electrostatic coating.
- the abrasive particles are heated prior to application e.g., from 30 to 150°C usually about 50°C.
- abrasive particles may be selected from those commonly used in the abrasive art, however, the abrasive particles (size and composition) can be chosen with the application of the abrasive article in mind. In choosing an appropriate abrasive particle, characteristics such as hardness, compatibility with the intended workpiece, particle size, reactivity with the workpiece, as well as heat conductivity may be considered.
- the composition of abrasive particles useful in the invention can be divided into two classes: natural abrasives and manufactured abrasives.
- Examples of natural abrasives include: diamond, corundum, emery, garnet, buhrstone, chert, quartz, sandstone, chalcedony, flint, quartzite, silica, feldspar, pumice and talc.
- Examples of manufactured abrasive include: boron carbide, cubic boron nitride, fused alumina, ceramic aluminum oxide, heat treated aluminum oxide, alumina zirconia, glass, silicon carbide, iron oxides, tantalum carbide, cerium oxide, tin oxide, titanium carbide, synthetic diamond, maganese dioxide, zirconium oxide, and silicon nitride.
- Abrasive particles useful in the invention typically and preferably have a particle size ranging from about 0.1 micrometer to about 1500 micrometers, more preferably ranging from about 0.1 micrometer to about 1300 micrometers.
- the abrasive particles preferably have an average particle size ranging from about 0.1 micrometer to about 700 micrometers, more preferably ranging from about 1 to about 150 micrometers, particularly preferably from about 1 to 80 micrometers. It is preferred that abrasive particles used in the invention have a Moh's hardness of at least 8, more preferably about 9; however, for specific applications, softer particles may be used.
- abrasive particle includes agglomerates of individual abrasive particles.
- An abrasive agglomerate is formed when a plurality of abrasive particles are bonded together with a binder to form a larger abrasive particle which may have a specific particulate structure.
- the plurality of particles which form the abrasive agglomerate may comprise more than on type of abrasive particle, and the binder used may be the same as or different from the binders used to bind the agglomerate to a backing.
- a size may be applied directly after application of the abrasive particles.
- the size is preferably water-based and may readily be applied by, e.g., spray-coating or roller-coating.
- the weight ratio of adhesive to water is generally within the range 10:1 to 1 :2, preferably from 1 :1 to 2:1.
- the coating weight is generally in the range from 1 to 250 g/m 2 solids and is normally dependent on the grade of abrasive particles.
- the material may be sprayed with water or placed in a moist environment to cure the adhesive.
- the material is dried, e.g., by force drying in a tunnel oven with infrared heaters. Suitable drying temperatures are about 60°C and drying times of about 90 seconds are usually sufficient.
- the abrasive article is preferably allowed to stand for a period of at least 24 hours to allow thorough curing.
- a particularly preferred product in accordance with the invention is an abrasive sponge, e.g., a foam strip of thickness in the range 2 to 15 mm having abrasive particles coated on one major surface.
- the substrate coated with abrasive particles can be in sheet form or as a web from a roll.
- the sponge may be formed in situ in the apparatus upstream of the coating station.
- Foam blocks, e.g., of a thickness about 25 mm may also be coated with abrasive particles in accordance with the present invention.
- the present invention is not limited to coating a single surface and articles having double sided abrasive coatings, which may be of different abrasive grades, may readily be prepared. Abrasive coating on some or all sides of a substrate is also possible.
- Example 1 A hot melt adhesive commercially available from Swift Adhesives
- Silicon carbide mineral (about 90 grams per square meter), commercially available from Arendal, Eydehavn, Norway, having the trade designation "P220" was drop coated on to the tacky, uncured coating at ambient temperature.
- a water-based urea/formaldehyde size mix commercially available from Dynochem, Duxford, Cambridgeshire, United Kingdom, under the trade designation "CBUL" was coated onto the samples described above. Drying/curing was effected for two hours at 80°C.
- the abrasive grains in the abrasive layer of the resulting product(s) felt sharp.
- a brief cut test was performed as follows: A sample of the coated abrasive article was converted into a 5.0 cm x 15 cm rectangular sheet and weighed. A dry brush and a sheet of paper were also weighed. The paper was larger than a wooden panel which was precoated with a water based acrylic lacquer commerically available from Granyte Surface Coatings PLC, Salford, England. The rectangular coated abrasive article was wrapped around a 5 cm x 2.5 cm rubber block having about a 60 degree International Rubber Hardness.
- the abrasive article on the rubber block was moved in push-pull strokes against the wooden panel sanding the acrylic lacquer.
- a stroke was the movement of the operator's hand in a straight line back and forth motion covering about 25 cm ⁇ 5 cm in each motion.
- the brush was used to transfer any dust on the wooden panel to the paper.
- the weight of acrylic lacquer removed was determined by reweighing the coated abrasive, brush, and paper. In this manual test, 0.2 grams of acrylic lacquer was removed in 60 strokes which demonstrates the abrasiveness of a coated abrasive article in accordance with the present invention.
- a polyester film was slot coated with a hot melt adhesive commercially available from Swift Adhesives Ltd., Twickenham, United
- Silicon carbide mineral commercially available Arendal, Eydehavn,
- a water-based phenol-formaldehyde resin was coated over as a size.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Polishing Bodies And Polishing Tools (AREA)
- Adhesives Or Adhesive Processes (AREA)
- Detergent Compositions (AREA)
Abstract
Priority Applications (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| BR9508534A BR9508534A (pt) | 1994-08-10 | 1995-07-24 | Artigo abrasivo |
| EP95928121A EP0775035B1 (fr) | 1994-08-10 | 1995-07-24 | Article abrasif |
| JP8507344A JPH10504245A (ja) | 1994-08-10 | 1995-07-24 | 研磨物品 |
| DE69505140T DE69505140T2 (de) | 1994-08-10 | 1995-07-24 | Schleifartikel |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB9416179.1 | 1994-08-10 | ||
| GB9416179A GB2292154A (en) | 1994-08-10 | 1994-08-10 | Abrasive elements comprising adhesives cross-linked via silyl groups |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO1996005022A1 true WO1996005022A1 (fr) | 1996-02-22 |
Family
ID=10759692
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US1995/009316 WO1996005022A1 (fr) | 1994-08-10 | 1995-07-24 | Article abrasif |
Country Status (8)
| Country | Link |
|---|---|
| EP (1) | EP0775035B1 (fr) |
| JP (1) | JPH10504245A (fr) |
| BR (1) | BR9508534A (fr) |
| CA (1) | CA2195546A1 (fr) |
| DE (1) | DE69505140T2 (fr) |
| ES (1) | ES2124009T3 (fr) |
| GB (1) | GB2292154A (fr) |
| WO (1) | WO1996005022A1 (fr) |
Families Citing this family (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2314791B (en) * | 1996-07-04 | 1999-09-01 | Evode Ltd | Polymeric coatings |
| EP1790703B1 (fr) * | 1998-04-24 | 2014-07-30 | JGC Catalysts and Chemicals Ltd. | Liquide de revêtement utilisé pour former un film à base de silice présentant une faible constante diélectrique et substrat sur lequel est couché un film à faible constante diélectrique |
| US9212300B2 (en) | 2007-08-10 | 2015-12-15 | Henkel Ag & Co. Kgaa | Reactive hot melt adhesive |
| US8440304B2 (en) | 2008-09-16 | 2013-05-14 | Henkel Corporation | Acrylic pressure sensitive adhesive formulation and articles comprising same |
| US8101276B2 (en) | 2008-09-16 | 2012-01-24 | Henkel Corporation | Pressure sensitive adhesive compositions and articles prepared using such compositions |
| CN102782073B (zh) | 2009-12-22 | 2014-11-12 | 汉高公司 | 湿固化热熔粘合剂 |
| US9365751B2 (en) | 2012-07-24 | 2016-06-14 | Henkel IP & Holding GmbH | Reactive hot melt adhesive |
| RU2652254C2 (ru) | 2013-01-24 | 2018-04-25 | ХЕНКЕЛЬ АйПи ЭНД ХОЛДИНГ ГМБХ | Реактивный клей-расплав |
| KR102277661B1 (ko) | 2014-01-14 | 2021-07-16 | 헨켈 아이피 앤드 홀딩 게엠베하 | 접착력이 개선된 반응성 핫 멜트 접착제 |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4027435A (en) * | 1969-05-08 | 1977-06-07 | Norton Company | Coated abrasive article containing a polyurethane adhesive splice |
| US4525177A (en) * | 1983-03-03 | 1985-06-25 | Grimes Philip M | Method of making coated abrasive disc |
| DE3702242A1 (de) * | 1986-03-14 | 1987-09-17 | Hochvakuum Dresden Veb | Verfahren zur herstellung haftfester ic-schichten |
| EP0577951A1 (fr) * | 1992-05-27 | 1994-01-12 | Matsushita Electric Industrial Co., Ltd. | Agent de finissage et méthode pour son utilisation |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH02140220A (ja) * | 1988-11-21 | 1990-05-29 | Kanegafuchi Chem Ind Co Ltd | 硬化性樹脂組成物 |
| US5213589A (en) * | 1992-02-07 | 1993-05-25 | Minnesota Mining And Manufacturing Company | Abrasive articles including a crosslinked siloxane, and methods of making and using same |
| US5250085A (en) * | 1993-01-15 | 1993-10-05 | Minnesota Mining And Manufacturing Company | Flexible bonded abrasive articles, methods of production and use |
-
1994
- 1994-08-10 GB GB9416179A patent/GB2292154A/en not_active Withdrawn
-
1995
- 1995-07-24 WO PCT/US1995/009316 patent/WO1996005022A1/fr active IP Right Grant
- 1995-07-24 EP EP95928121A patent/EP0775035B1/fr not_active Expired - Lifetime
- 1995-07-24 DE DE69505140T patent/DE69505140T2/de not_active Expired - Fee Related
- 1995-07-24 JP JP8507344A patent/JPH10504245A/ja active Pending
- 1995-07-24 BR BR9508534A patent/BR9508534A/pt not_active Application Discontinuation
- 1995-07-24 CA CA 2195546 patent/CA2195546A1/fr not_active Abandoned
- 1995-07-24 ES ES95928121T patent/ES2124009T3/es not_active Expired - Lifetime
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4027435A (en) * | 1969-05-08 | 1977-06-07 | Norton Company | Coated abrasive article containing a polyurethane adhesive splice |
| US4525177A (en) * | 1983-03-03 | 1985-06-25 | Grimes Philip M | Method of making coated abrasive disc |
| DE3702242A1 (de) * | 1986-03-14 | 1987-09-17 | Hochvakuum Dresden Veb | Verfahren zur herstellung haftfester ic-schichten |
| EP0577951A1 (fr) * | 1992-05-27 | 1994-01-12 | Matsushita Electric Industrial Co., Ltd. | Agent de finissage et méthode pour son utilisation |
Also Published As
| Publication number | Publication date |
|---|---|
| CA2195546A1 (fr) | 1996-02-22 |
| EP0775035B1 (fr) | 1998-09-30 |
| ES2124009T3 (es) | 1999-01-16 |
| GB9416179D0 (en) | 1994-09-28 |
| EP0775035A1 (fr) | 1997-05-28 |
| DE69505140T2 (de) | 1999-06-02 |
| GB2292154A (en) | 1996-02-14 |
| BR9508534A (pt) | 1998-07-21 |
| DE69505140D1 (de) | 1998-11-05 |
| JPH10504245A (ja) | 1998-04-28 |
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