Abrasive tool making process – material – or composition – Impregnating or coating an abrasive tool
Patent
1997-11-12
1999-12-28
Marcheschi, Michael
Abrasive tool making process, material, or composition
Impregnating or coating an abrasive tool
51309, 51294, 51298, 51299, 51296, B24D 328
Patent
active
060075902
DESCRIPTION:
BRIEF SUMMARY
The invention is generally related to a method of making a foraminous abrasive article with use of a labile foamed binder as a transitory abrasive particle barrier by which abrasive particles are preferentially bonded to external surface regions of a foraminous substrate.
BACKGROUND OF THE INVENTION
Foraminous abrasive articles have been made, for example, as nonwoven abrasive articles constituted of a network of synthetic fibers or filaments which provide surfaces upon which abrasive particles are adhesively attached.
Nonwoven abrasive articles, in particular, are useful in various converted forms, such as wheels, sheets, discs, flap brushes, and the like. In these converted forms, the resulting nonwoven abrasive articles are useful to clean, condition, and/or decorate the surfaces such materials as metal, wood, plastics, glass, ceramics, composites, and the like. A particularly important use for such nonwoven abrasive articles is to scuff automotive body finishes prior to the application of further coatings.
Conventional nonwoven abrasive articles generally involve a mat of fibers which have on at least a portion of their surface an abrasive coating comprising abrasive particles and a binder. As known, the fibers can be formed from various synthetic polymers, including polyamides, polyesters, polypropylene, polyethylene, and various copolymers thereof. Also, naturally occurring fibers such as cotton, wool, bast fibers, and various animal hairs may also be suitable. Suitable abrasive particles can be formed of flint, garnet, aluminum oxide, diamond, silicon carbide, and the like. Binders commonly comprise cured versions of hide glue or varnish, or one or more resins such as phenolic, urea-formaldehyde, melamine-formaldehyde, urethane, epoxy, and acrylic resins. Phenolic resins include those of the phenol-aldehyde type.
In one conventional general scheme, nonwoven abrasive articles have been manufactured by applying to a nonwoven web starting material a "prebond" coating of binder precursor solution, which includes one or more of the above-named resins, in order to impart sufficient strength to the nonwoven web starting material so that it can better tolerate subsequent processing. A "make" coating optionally has been applied to the prebonded nonwoven web and left non-fully cured up until the time when abrasive particles are later applied to the web to help attach the abrasive grains throughout the lofty fibrous mat. Finally, an abrasive coating of resinous binder material and abrasive particles has been applied onto the nonwoven to increase the abrasive characteristics of the nonwoven. The resin binder used in the various coatings may be the same or different.
In a conventional approach, the binder coating for the abrasive particles has been applied to the nonwoven web as a non-foamed dispersion of a binder resin and abrasive particles in a liquid medium. The dispersion is then applied to the nonwoven substrate by means, such as spraying, that either atomizes the mixture to atomized droplets, or otherwise causes a film of the dispersion to be formed on the web. The atomized droplets or film are applied to the nonwoven web and cured. During curing, the droplets either flow together (coalesce) by heat-induced viscosity reduction, or cure as individual droplets where they stand. Films usually flow together to cover (wet) most of the filaments in the nonwoven web, and they are cured in position.
As the binder resin, phenolic resins are used extensively to manufacture nonwoven abrasive articles because of their thermal properties, availability, low cost, and ease of handling. The monomers currently used in greatest volume to produce phenolic resins are phenol and formaldehyde. Other important phenolic starting materials are the alkyl-substituted phenols, including cresols, xylenols, p-tert-butylphenol, p-phenylphenol, and nonylphenol. Diphenols, e.g., resorcinol (1,3-benzenediol) and bisphenol-A (bis-A or 2,2-bis(4-hydroxyphenyl)propane), are employed in smaller quantities for applications requiring special
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3M Innovative Properties Company
Bardell Scott A.
Marcheschi Michael
Pastirik Daniel R.
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