U.S. patent application number 13/862592 was filed with the patent office on 2013-08-29 for methods for producing a coated abrasive article for polishing or lapping applications.
The applicant listed for this patent is Olivier L. Guiselin. Invention is credited to Olivier L. Guiselin.
Application Number | 20130219800 13/862592 |
Document ID | / |
Family ID | 42129733 |
Filed Date | 2013-08-29 |
United States Patent
Application |
20130219800 |
Kind Code |
A1 |
Guiselin; Olivier L. |
August 29, 2013 |
Methods for Producing a Coated Abrasive Article for Polishing or
Lapping Applications
Abstract
Methods are provided for forming an abrasive coating on a
surface of a backing. An abrasive slurry includes a continuous
phase, a first discontinuous phase of abrasive particles dispersed
in the continuous liquid phase, and a second discontinuous phase of
binder precursor particles dispersed in the continuous liquid
phase, so that the continuous liquid phase carries the first and
second discontinuous phases. A coated abrasive article is formed by
coating the abrasive slurry onto the surface of the backing, and
then removing the continuous phase.
Inventors: |
Guiselin; Olivier L.;
(Dayton, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Guiselin; Olivier L. |
Dayton |
OH |
US |
|
|
Family ID: |
42129733 |
Appl. No.: |
13/862592 |
Filed: |
April 15, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12604849 |
Oct 23, 2009 |
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13862592 |
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61110989 |
Nov 4, 2008 |
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Current U.S.
Class: |
51/298 ; 51/307;
51/308; 51/309 |
Current CPC
Class: |
C09D 7/68 20180101; C08K
9/02 20130101; C09D 5/28 20130101; C09D 7/67 20180101; B24D 3/00
20130101; C09D 7/69 20180101; B24D 3/28 20130101; C09D 7/45
20180101; C08K 3/10 20130101; C09K 3/1463 20130101; B24D 11/00
20130101; C08K 9/04 20130101; C09D 7/62 20180101 |
Class at
Publication: |
51/298 ; 51/307;
51/309; 51/308 |
International
Class: |
B24D 3/28 20060101
B24D003/28 |
Claims
1. A method of manufacturing a coated abrasive article comprising:
(a) providing a flexible backing having a surface configured for
being coated with an abrasive coating; (b) providing an abrasive
slurry including a continuous liquid phase, which comprises at
least 50% per weight of water, and at least 0.001% per weight of
fluorosurfactant; a first discontinuous phase including abrasive
particles dispersed in the continuous liquid phase; and a second
discontinuous phase including a waterborne binder precursor
particle dispersion in the continuous liquid phase, wherein the
continuous liquid phase carries the first and second discontinuous
phases, wherein the volume ratio of abrasive particles to binder
precursor particles is 0.05 to 3, and wherein the first and the
second discontinuous phases comprise between 5% and 60% of the
abrasive slurry by volume; (c) coating the abrasive slurry onto the
surface of the flexible backing; (d) removing at least 50% per
weight of the continuous liquid phase by evaporation; and (e)
coalescing the binder precursor particles at the surface of the
flexible backing to form a coating with solid continuous binder
phase disposed about the abrasive particles.
2. A method of manufacturing a coated abrasive article comprising:
(a) providing a flexible backing having a surface configured for
being coated with an abrasive coating; (b) providing an abrasive
slurry including a continuous liquid phase, which comprises at
least 60% per weight of water, and at least 0.001% per weight of
fluorosurfactant; a first discontinuous phase including abrasive
particles dispersed in the continuous liquid phase; and a second
discontinuous phase including a waterborne binder precursor
particle dispersion in the continuous liquid phase, wherein the
continuous liquid phase carries the first and second discontinuous
phases, wherein the volume ratio of abrasive particles to binder
precursor particles is 0.05 to 3, wherein the first and the second
discontinuous phases comprise between 5% and 60% of the abrasive
slurry by volume, and wherein the viscosity of the abrasive slurry
is less than 100,000 cP; (c) coating the abrasive slurry onto the
surface of the flexible backing; (d) removing at least 60% per
weight of the continuous liquid phase by evaporation; and (e)
coalescing the binder precursor particles at the surface of the
flexible backing.
3. The method of claim 2, wherein the continuous liquid phase
comprises at least about 90% per weight of water and wherein the
abrasive and binder precursor particles comprise between 5% and 50%
of the slurry by volume and the method comprises removing at least
90% per weight of the continuous liquid phase by evaporation.
4. The method of claim 2, wherein the coalesced binder precursor
particles form a continuous phase around the abrasive
particles.
5. The method of claim 4, wherein the continuous liquid phase
comprises at least one coalescing agent configured to reduce the
film forming temperature of the binder precursor particle
dispersion.
6. The method of claim 5, wherein the waterborne binder precursor
particle dispersion is selected from the group consisting of
waterborne acrylics emulsion, waterborne polyurethanes dispersion,
waterborne urethane-acrylic copolymers dispersion, waterborne
polyesters dispersion, waterborne alkyds dispersion, waterborne
epoxies dispersion, waterborne phenoxy dispersion, waterborne
melamine dispersion, waterborne polyamide dispersion, waterborne
polyimide dispersion, waterborne cyanate esters dispersion, and
combinations thereof.
7. The method of claim 2 wherein the second discontinuous phase
comprises a cross-linkable resin, the method comprising thermally
curing the abrasive slurry coating using at least one energy
source.
8. The method of claim 7, comprising transmitting energy from the
energy source by convection, conduction, radiation, or combinations
thereof.
9. The method of claim 7, the continuous liquid phase comprises a
curing agent selected from the group consisting of metal ion
crosslinkers, polyaldehydes, polyaziridines, polyisocyanates,
polysulfides, imidazoles, dicyandiamines, polyamidoamines,
polyamides, polyamines, functionalized silanes, functionalized
siloxane, carbodiimides, peroxides, and combinations thereof.
10. The method of claim 2, wherein the second discontinuous phase
comprises binder precursor particles of: at least about 5
nanometers in size; and up to about 50 micrometers in size.
11. The method of claim 10, wherein the second discontinuous phase
comprises binder precursor particles of: at least about 10
nanometers in size; and up to about 10 micrometers in size.
12. The method of claim 11, wherein the second discontinuous phase
comprises binder precursor particles of: at least about 50
nanometers in size; and up to about 2 micrometers in size.
13. The method of claim 2, wherein the abrasive particles are
selected from the group consisting of natural diamond, synthetic
diamond, cubic boron nitride, aluminum oxide, heat treated aluminum
oxide, white fused aluminum oxide, black silicon carbide, green
silicon carbide, titanium diboride, boron carbide, tungsten
carbide, titanium carbide, garnet, fused alumina zirconia, sol gel
abrasive material, silica, silicate, iron oxide, zirconium oxide,
titanium dioxide, tin oxide, cerium oxide, rare earth containing
ceramic materials, aluminum oxide containing ceramic material,
zirconium oxide, chromium oxide, and mixtures thereof.
14. The method of claim 2, wherein the abrasive slurry comprises at
least one adhesion promoter selected from the group consisting of
silanes, titanates, zirconates, phosphates, phosphonates,
phosphinates, and combinations thereof.
15. The method of claim 2, wherein the abrasive slurry further
comprises a foam control agent.
16. The method of claim 2, wherein the abrasive slurry further
comprises a wetting agent.
17. The method of claim 2, wherein the abrasive slurry comprises a
rheology modifier and the weight ratio of the rheology modifier to
the quantity of water in the slurry is between 0.0005 and 0.10
whereby the viscosity of the abrasive slurry is adjusted to a value
between 10 cP and 50,000 cP.
18. The method of claim 2, wherein the flexible backing is selected
from the group consisting of plastic film, metallic foil, cloth,
paper, foam and combinations thereof.
19. A method of manufacturing a coated abrasive article comprising:
(a) providing a flexible backing having a surface configured for
being coated with an abrasive coating, wherein the flexible backing
is selected from the group consisting of plastic film, metallic
foil, cloth, paper, foam and combinations thereof; (b) providing an
abrasive slurry including a continuous liquid phase, which
comprises at least 90% per weight of water, and at least 0.01% per
weight of fluorosurfactant; a first discontinuous phase including
abrasive particles dispersed in the continuous liquid phase; and a
second discontinuous phase including a waterborne binder precursor
particle dispersion in the continuous liquid phase, wherein the
continuous liquid phase carries the first and second discontinuous
phases, wherein the volume ratio of abrasive particles to binder
precursor particles is 0.05 to 2, and wherein the first and the
second discontinuous phases comprise between 10% and 40% of the
abrasive slurry by volume; wherein the waterborne binder precursor
particle dispersion is selected from the group consisting of
waterborne acrylics emulsion, waterborne polyurethanes dispersion,
waterborne urethane-acrylic copolymers dispersion, waterborne
polyesters dispersion, waterborne alkyds dispersion, waterborne
epoxies dispersion, waterborne phenoxy dispersion, waterborne
melamine dispersion, waterborne polyamide dispersion, waterborne
polyimide dispersion, waterborne cyanate esters dispersion, and
combinations thereof; wherein the continuous liquid phase comprises
a curing agent selected from the group consisting of metal ion
crosslinkers, polyaldehydes, polyaziridines, polyisocyanates,
polysulfides, imidazoles, dicyandiamines, polyamidoamines,
polyamides, polyamines, functionalized silanes, functionalized
siloxane, carbodiimides, peroxides, and combinations thereof. (c)
coating the abrasive slurry onto the surface of the flexible
backing; (d) removing at least 90% per weight of the continuous
liquid phase by evaporation; (e) coalescing the binder precursor
particles at the surface of the flexible backing to form a coating
with solid continuous binder phase disposed about the abrasive
particles; and (f) thermally curing the coating using at least one
energy source.
20. The method of claim 19, wherein the continuous liquid phase
comprises at least 0.02% per weight of fluorosurfactant.
Description
BACKGROUND
[0001] 1. Technical Field
[0002] This invention relates to coated abrasives, and particularly
to an abrasive slurry having a binder precursor in a discontinuous
phase.
[0003] 2. Background Information
[0004] Throughout this application, various publications, patents
and published patent applications are referred to by an identifying
citation. The disclosures of the publications, patents and
published patent applications referenced in this application are
hereby incorporated by reference into the present disclosure.
[0005] Coated abrasive articles for polishing or lapping
applications are used to work a particulate abrasive material
against the surface of a work-piece until the surface has a fine
and well controlled finish. Generally it is desirable to attain a
very smooth surface finish while obtaining and retaining a high
degree of dimensional control so that the resulting product will
conform to very precise finish and size standards.
[0006] As shown in FIG. 1, most conventional coated abrasives are
made by first applying a thin coating of adhesive 6 called a "make
coat" to a flexible substrate 20 such as cloth, paper, or polyester
film. Abrasive particles 12 are then deposited via a process in
which the particles are projected, e.g., electrostatically, onto
the make coat. By using an electrostatic field, the particles may
be oriented vertically, resulting in a product with a more
aggressive cut. A second binder coating 7, called a "size coat", is
applied on top of the particles to firmly anchor the particles to
the coated abrasives.
[0007] Lapping films are typically made by a slurry coating
process. In this process, adhesive binder is dissolved in an
organic solvent, blended with filler particles, and deposited as a
slurry onto the substrate film 20. The solvent is evaporated,
leaving behind the filler and adhesive, which is cured to form a
solid coating. The resulting coating 8 contains the abrasive
particles 12 oriented in a random fashion, as shown in FIG. 2.
[0008] Because of the way they are made, lapping films generally do
not cut as aggressively as conventional coated abrasives, but they
yield a relatively fine finish. The specific requirements of a
given grinding or finishing application dictate whether
conventional coated abrasives or lapping films are used; in some
cases, both types of product are used.
[0009] As shown in FIG. 3, conventional slurries 10 used to make
lapping films typically consist of an adhesive dissolved in an
organic solvent, forming a continuous phase 16, into which the
abrasive particles 12 are blended. A key drawback of such a system
is that large amounts of solvent are required to dissolve the
adhesive and to have a solution that is fluid enough to be coated.
It is not unusual to have solvent-adhesive blends in which the
adhesive comprises less than 15% by weight of the mix.
[0010] One such conventional approach used to manufacture coated
abrasive articles for lapping or polishing applications is
described in U.S. Pat. No. 7,235,296. The abrasive slurry includes
abrasive particles that form a discontinuous phase. The continuous
phase is a liquid including an organic solvent such as various
alcohols, glycol ethers, glycol ether acetates, lactates,
hydrocarbons, ketones, ethers, acetates, methyl ethyl ketone (MEK)
or toluene, and a binder precursor.
[0011] Another conventional approach is disclosed in U.S. Pat. No.
6,958,082, which teaches the manufacture of a polishing film for
the surface finishing of precision instruments such as optical
fiber connectors for communications, color filters for LCD, optical
lenses, magnetic disk substrates, and semiconductor wafers.
Polishing films according to U.S. Pat. No. 6,958,082 are produced
by applying a paint like material including ultra fine silica
particles (20 nm), a conventional polyurethane or polyester resin
binder precursor, and an organic solvent (MEK) on the surface of a
plastic film and then drying it to form a polishing layer on the
surface of the plastic film.
[0012] Conventional lapping film adhesives require relatively large
amounts of solvent because of a well-known relationship in polymer
science stating that the viscosity of a solution of adhesive
polymer is a function of the concentration of the polymer in the
solvent and the polymer's molecular weight, both raised to the
power 3.4, as shown in the following equation 1 established by G.
C. Berry and T. G. Fox in an article entitled "The viscosity of
polymers and their concentrated solutions" Adv. Polymer Science
Volume 5 pages 261-357 (1968):
.eta.=K(cM).sup.3,4 (Eq. 1)
where:
[0013] .eta. is the viscosity of the solution,
[0014] K is a constant,
[0015] c is the concentration of the adhesive polymer in the
solution, and
[0016] M is the molecular weight of the polymer
[0017] Small increases in either concentration or molecular weight
result in relatively large increases in viscosity, which can make
the coating solution too viscous to coat. It should be noted also
that this effect becomes more and more pronounced at higher and
higher concentrations or molecular weights. This limits the coating
formulator in both the concentration and the molecular weight of
the polymer that can be used for the adhesive system. The effect of
molecular weight on viscosity thus militates against the use of
adhesive systems whose properties may be improved by the use of
relatively high molecular weight and/or highly concentrated
adhesives.
[0018] The consequences of these limitations are significant. The
large amounts of organic solvent required pose health, safety, and
environmental concerns, including exposure of workers to noxious
vapors, risks of fire and explosions, and release of VOCs, which
generally require expensive capital investment in incinerators to
mitigate, and which still tend to generate a substantial carbon
footprint. In recent years environmental and other factors have
spurred the coatings industry to use water-based coatings as an
alternative to solvent-based coatings. Although a water-based
system is in many respects more desirable than a solvent-based
system, there are a number of challenges to overcome to make such a
system viable. One such challenge is the relatively high surface
tension of water, which causes it to bead up rather than spread out
and uniformly wet a substrate (most commonly used organic solvents
have low surface tensions and do not have this problem). To
overcome this, surfactants are generally selected that reduce the
surface tension of water and allow it to wet out a substrate.
However, many of these surfactants cause excessive foaming.
Therefore, another challenge is to reduce or suppress foam.
However, most of the anti-foam or de-foaming agents available for
water-based systems cause coating defects such as "fisheyes".
Additives can also adversely affect other final properties of the
coating; for example, they can reduce adhesion, reduce water
resistance, or reduce mechanical properties. These, the
aforementioned molecular weight issues, and other technical
challenges, can make formulating a viable water-based lapping film
slurry formulation a complex and difficult undertaking.
[0019] Thus, a need exists for a system and method that addresses
the aforementioned drawbacks.
SUMMARY
[0020] In a first aspect of the invention, an abrasive slurry is
configured to form an abrasive coating on a surface of a backing.
The abrasive slurry includes a continuous phase, a first
discontinuous phase of abrasive particles dispersed in the
continuous liquid phase, and a second discontinuous phase of binder
precursor particles dispersed in the continuous liquid phase, so
that the continuous liquid phase carries the first and second
discontinuous phases.
[0021] In a variation of the first aspect of the invention, the
continuous phase includes water.
[0022] Another aspect of the invention, a coated abrasive article
includes a backing having a surface configured for being coated
with an abrasive coating. An abrasive coating is disposed on the
surface, formed from the abrasive slurry of the first aspect of the
invention, or the variation thereof, as described above. The
coating includes a coalesced second discontinuous phase in the form
of a solid continuous binder phase disposed about the abrasive
particles of the first discontinuous phase.
[0023] In still another aspect of the invention, a method of
manufacturing a coated abrasive article includes providing a
backing having a surface configured for being coated with an
abrasive coating, and providing an abrasive slurry including a
continuous liquid phase, a first discontinuous phase including
abrasive particles dispersed in the continuous liquid phase, and a
second discontinuous phase including binder precursor particles
dispersed in the continuous liquid phase. The abrasive slurry is
coated onto the surface of the backing, and the continuous phase is
removed, such as by evaporation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] For a better understanding of the present invention,
reference may be made to the accompanying drawing.
[0025] FIG. 1 is a cross-sectional schematic view of a coated
abrasive product of the prior art;
[0026] FIG. 2 is a cross-sectional schematic view of lapping film
of the type produced by embodiments of the present invention;
[0027] FIG. 3 is a schematic view of an abrasive slurry of the
prior art;
[0028] FIG. 4 is a schematic view of an embodiment of the abrasive
slurry of the present invention;
[0029] FIG. 5 is a schematic view, on an enlarged scale, of a
portion of the abrasive slurry of FIG. 3;
[0030] FIG. 6 is a schematic view, on an enlarged scale, of a
portion of the abrasive slurry of FIG. 4; and
[0031] FIG. 7 is a graph of viscosity versus adhesive polymer
concentration for the slurries of FIGS. 3 and 4.
DETAILED DESCRIPTION
[0032] In the following detailed description, reference is made to
the accompanying drawings that form a part hereof, and in which is
shown by way of illustration, specific embodiments in which the
invention may be practiced. These embodiments are described in
sufficient detail to enable those skilled in the art to practice
the invention, and it is to be understood that other embodiments
may be utilized. It is also to be understood that structural,
procedural and system changes may be made without departing from
the spirit and scope of the present invention. In addition,
well-known structures, circuits and techniques have not been shown
in detail in order not to obscure the understanding of this
description. The following detailed description is, therefore, not
to be taken in a limiting sense, and the scope of the present
invention is defined by the appended claims and their equivalents.
For clarity of exposition, like features shown in the accompanying
drawings are indicated with like reference numerals and similar
features as shown in alternate embodiments in the drawings are
indicated with similar reference numerals.
General Overview
[0033] Referring to FIG. 3, as mentioned above, coated abrasives
adapted for polishing or lapping applications are conventionally
derived from a slurry 10, which includes one discontinuous phase
(abrasive particles) 12, which is carried by one liquid continuous
phase 16. Generally the liquid continuous phase includes a solvent
and a resin or other binder precursor that is soluble in the
solvent.
[0034] In contrast, as shown in FIG. 4, embodiments of the present
invention include coated abrasive products for lapping or polishing
applications derived from a slurry 100, which includes at least two
discontinuous phases (the first discontinuous phase including
abrasive particles 12, and the second discontinuous phase including
resin particles or other binder precursors 114), which are carried
by a liquid continuous phase 116. The liquid continuous phase 116
may be solvent-based, or in particular embodiments, is water-based.
Aspects of the invention also include coated abrasives made using
this slurry 100, and include methods of coating a substrate
(backing) 20 using slurry 100.
[0035] Thus, instead of using a slurry in which the adhesive is
dissolved into the solvent phase, the instant invention addresses
the aforementioned drawbacks of conventional approaches by using a
slurry in which the adhesive is dispersed (e.g., as a dispersion or
emulsion) as a separate phase in the solvent. As a result, the
effects of molecular weight and concentration of the adhesive
polymer on the system viscosity are dramatically changed.
[0036] Although not wishing to be tied to any particular theory, in
the instant embodiments, it is understood that individual adhesive
polymer (i.e. binder precursor) molecules 114 are no longer
available in the liquid continuous phase 116 to entangle with other
polymer molecules 114 and increase viscosity. Instead, the adhesive
polymer molecules are grouped in larger domains that are dispersed
(or emulsified) in the liquid continuous phase 116. This is
believed to substantially sever the direct relationship between
viscosity and adhesive polymer molecular weight and concentration
commonly associated with the prior art.
[0037] Referring now to FIGS. 5 and 6, differences between the
prior art system of FIG. 3, and the embodiment of FIG. 4, are shown
at a molecular level. FIG. 5 shows dissolved polymer strands 22
entangling with each other, causing the viscosity to rise, while
FIG. 6 shows the discrete domains 114 of polymer groups having
polymer strands 122 that have significantly less opportunity to
entangle with strands 122 of other domains 114.
[0038] Because the polymer molecules are arranged in discrete
domains 114, the present inventor has realized that the effect of
concentration on viscosity in the instant embodiments is
characterized by the Maron-Pierce equation (Eq. 2), which is used
to describe the viscosity of suspensions:
.eta. .eta. s = ( 1 - c 0.68 ) - 2 ( Eq . 2 ) ##EQU00001##
[0039] where:
[0040] .eta. is the viscosity of the solution,
[0041] .eta..sub.s is the viscosity of the solvent and
[0042] c is the concentration of the adhesive polymer in the
solution
[0043] The graph of FIG. 7 compares the viscosity curves of the
conventional system of FIG. 3, in which the adhesive is dissolved
in the continuous solvent phase (.eta.1) and of the inventive
system of FIG. 4, in which the adhesive is dispersed in discrete
domains throughout the solvent phase (.eta.2). As shown, at
concentrations above 15% adhesive, the viscosity of the
conventional system is too high to be coated by the coating methods
well known in the art (500,000 cP). However, when the adhesive is
in the form of discrete domains in accordance with the instant
invention (dashed line), concentrations of 40% or more adhesive are
viable.
[0044] Thus, instead of a system in which the adhesive is dissolved
into a solvent carrier, embodiments of the present invention
provide a system in which the adhesive is dispersed as discrete
domains (a "second discontinuous phase"). This approach permits the
use of slurries having relatively high solids content (e.g., up to
40% or more)--and consequently significantly lower solvent
content--while providing relatively broad formulation latitude by
not being limited to adhesives having only relatively low-molecular
weights.
[0045] Slurries of the present invention may be coated using
substantially the same process(es) as used to coat conventional
slurries made with dissolved adhesive. Once coated, the product is
dried to drive off the coating to permit the adhesive to coalesce
to form a continuous coating. This drying may also include curing,
such as in the event reactive materials are used, as discussed in
greater detail hereinbelow.
[0046] In embodiments of the present invention, water may be used
as the continuous carrier phase, to provide the added benefit of
having a coating free of organic solvent. (It is noted that in some
embodiments, a small amount of co-solvent may be included to
facilitate processing) This may substantially reduce or eliminate
the health, safety, and environmental concerns commonly associated
with conventional solvent-based systems, as discussed hereinabove.
It is noted that the placement of the adhesive in a second
discontinuous phase also enables one to use relatively high
molecular weight adhesives (binder precursors) that may
substantially mitigate many of the drawbacks associated with the
aforementioned conventional water-based systems. Embodiments of the
present invention also include coated abrasive articles for lapping
or polishing applications, which are manufactured by coating the
waterborne abrasive slurry of the invention onto a backing and
drying/curing the slurry. Embodiments also include methods of
making the abrasive articles.
[0047] The features and advantages described herein are not
all-inclusive and, in particular, many additional features and
advantages will be apparent to one of ordinary skill in the art in
view of the drawings, specification, and claims. Moreover, it
should be noted that the language used in the specification has
been principally selected for readability and instructional
purposes, and not to limit the scope of the inventive subject
matter.
[0048] Where used in this disclosure, the term "Binder" refers to
the composition which binds abrasive particles to a backing in the
final product. "Binder precursor" refers to the components of the
binder as they exist in the slurry prior to drying and/or curing of
the coating. Thus, as used herein, the terms "binder" and "binder
precursor" refer to substantially any material capable of securing
the abrasive particles to the backing, including adhesives, resins,
polymers, oligomers, pre-polymers, glues, bonds, etc. The terms
"slurry" or "abrasive slurry" refer to a coatable liquid
composition that includes a liquid carrier, abrasive particles and
binder precursor particles dispersed in the liquid carrier, and
optionally additional additives. The term "surfactant" refers to a
surface active agent which migrates to the interface between two
phases. The term "dispersant" refers to a surfactant configured to
disperse a discontinuous phase in a liquid carrier. The terms
"water-based" and "waterborne" refer to a composition in which the
liquid continuous phase comprises water as the primary constituent.
The term "organic solvent" refers to any liquid whose molecules
comprises at least one carbon atom. The term "solvent-based" refers
to a composition in which the liquid continuous phase comprises
organic solvents as primary constituents. The term "abrasive slurry
base" refers to an abrasive particle dispersion, which may include
water or other solvents as the liquid carrier, and includes
dispersed abrasive particles, and optionally additives such as for
example, dispersants, foam control agents, inorganic pigments,
inorganic fillers, adhesion promoters, viscosity modifiers, but
little or no binder precursor particles. The terms "binder
precursor liquid composition" and "resin liquid composition" refer
to a binder precursor dispersion, emulsion, or colloidal suspension
with particles ranging in size from 5 nm to 50 microns and in
either liquid or solid state. The binder precursor liquid
composition includes a liquid carrier such as water or other
solvents, dispersed binder precursor particles, and optionally
additives such as surfactants and/or dispersants to stabilize the
binder precursor particles, foam control agents, co-solvents,
coalescing agents, organic pigments, and soluble adhesion
promoters, but no abrasive particles. A wide range of resin
dispersions, emulsions, or colloidal suspensions may be used as the
binder precursor liquid composition.
[0049] Having generally described embodiments of the invention,
specific aspects of the invention will now be described in greater
detail.
[0050] Particular embodiments of an abrasive slurry according to
this invention include the following: [0051] A waterborne
continuous liquid phase including water, which acts as carrier. In
addition this phase may contain various additives which are soluble
in water such as a small amount of co-solvent. [0052] A first
discontinuous phase formed by abrasive particles dispersed in the
continuous phase. Dispersants may be used to properly disperse the
abrasive particles in water. This first discontinuous phase may
also include fillers or secondary abrasive particles if necessary.
[0053] A second discontinuous phase made of binder precursor
particles dispersed in the continuous phase. Surfactants, charged
polymer end groups, or polymeric dispersants may be used to
stabilize the binder precursor particles in the continuous phase.
The binder precursor can be a reactive binder precursor such as
thermosetting binders, crosslinking binders, and binders curable by
an additional polymerization, or a non-reactive binder precursor
such as a thermoplastic polymer that needs only drying, without
additional reactive curing, to solidify. [0054] Additional optional
additives such as curing agents, coloring agents (e.g., pigments,
dyes, etc.), wetting agents, foam control agents, water compatible
adhesion promoters, viscosity modifiers, acids, bases, or buffers
to control pH, film coalescing agents, antistatic agents, etc. may
be incorporated into the slurry. Additives such as dispersants,
coupling agents, fillers, curing agents, hardening agents,
photo-initiators, surfactants, wetting agents, coloring agents
(e.g., pigments, dyes), anti-oxidants, antistatic agents, etc.
[0055] The water based slurry may be uniformly applied over a
flexible backing 20 by a variety of methods, including gravure roll
coating, curtain coating, slot die coating, knife coating, spray
coating, or any other coating method known in the art, and then
dried/cured.
[0056] Coated abrasives in accordance with the present invention
have been found to have surprisingly good coating quality and
performance for lapping or polishing applications. In addition, the
slurry of the invention is environmentally attractive and cost
effective since: [0057] The waterborne process of the invention has
relatively low VOC (Volatile Organic Compound) content. [0058] The
waterborne slurry process requires substantially no abatement or
solvent recovery equipment and thus generally requires a lower
capital investment than prior solvent-based approaches. [0059] The
second discontinuous phase enables the use of high molecular weight
resins without the adverse effects on viscosity as discussed
hereinabove.
Abrasive Article Backing
[0060] Embodiments of the present invention may be applied to
substantially any type of backing (substrate) 20. Such suitable
backings include polymeric film, cloth, paper, nonwovens, open
mesh, foams, metallic foil, and combinations thereof. Examples of
polymeric films include, but are not limited to, polyester,
polyester and co-polyester, microvoided polyester films, PEN,
polyimide films, polyamide films, polyvinyl alcohol films,
polypropylene film, polyethylene film and the like. In particular
embodiments, a treatment may be applied to the backing/substrate 20
for better adhesion. Typical examples of treatments include surface
alterations such as corona treatment, UV treatment, electron beam
treatment, flame treatment, scuffing, and primer coatings.
[0061] The backing 20 should be sufficiently strong to support the
binder and abrasive particles. Additionally it should be
sufficiently flexible to allow mounting on the surface of the
particular tool (e.g., polishing or lapping tool) of interest.
Generally it is desirable that the backing be smooth and of uniform
caliper in embodiments intended for finishing high precision
articles.
Abrasive Particles
[0062] A wide range of abrasive particles may be used in the
various embodiments of present invention, and may be classified as
follows: [0063] Superabrasive particles such as natural diamond,
synthetic diamond, and cubic boron nitride. [0064] Hard abrasive
particles such as aluminum oxide, heat treated aluminum oxide,
white fused aluminum oxide, black silicon carbide, green silicon
carbide, titanium diboride, boron carbide, tungsten carbide,
titanium carbide, garnet, fused alumina zirconia, sol gel abrasive
particles and the like. [0065] Soft abrasive particles such as
silica, silicates, iron oxide, zirconium oxide, titanium dioxide,
and tin oxide. [0066] Chemically reactive abrasive particles such
as cerium oxide, rare earth compounds, zirconium oxide, chromium
oxide, or mixtures thereof. It is believed that such chemically
reactive abrasive particles may provide a chemo-mechanical element
to the polishing procedure. As used herein, chemo-mechanical refers
to a dual mechanism where corrosion chemistry and fracture
mechanics may both play a role in glass polishing. Chemically
reactive abrasive particles may be especially useful in glass
polishing operations.
[0067] The average size of the abrasive particles may vary between
5 nanometers and 200 micrometers, and more typically, between 10
nanometers and 100 micrometers. In particular embodiments it may be
desirable to use a relatively tightly graded particle size
distribution, or use a blend of particle sizes, or a blend of
particle types, or combinations thereof, to achieve particular
finish or performance effects.
[0068] It is also within the scope of this invention to use surface
treated abrasive particles. The surface treatment may be used to
increase the adhesion to the binder and alter the abrading
characteristics of the abrasive particles.
[0069] Still further, in some embodiments of this invention, the
first discontinuous phase may include aggregates of smaller primary
abrasive particles.
Binder Precursors
[0070] In particular embodiments, the binder precursor particles
114 should be more than 5 nm in size (e.g., in their largest
dimension). Generally, the binder precursor particles size is less
than 50 microns, preferably less than 10 microns, and more
preferably less than 2 microns. Specific examples of suitable
binder precursor liquid compositions for this invention have a
particle size between 50 and 500 nanometers.
[0071] The binder precursor particles 114 may include monomers,
oligomers, pre-polymers, or polymers.
[0072] The binder precursor may be reactive and have functional
groups such as vinyl, alcohol, methylol, aldehyde, ketone, phenol,
ester, epoxy, acyl halide, carboxylate, amide, amine, imine,
nitrile, isocyanate, thiol, sulfonyl, acrylate, methacrylate,
silanol, and any other functional group or combinations thereof
used in the art.
[0073] Additionally the binder precursor may also be a
thermoplastic polymer.
[0074] The physical state of the binder precursor particles may be
liquid or solid. The binder precursor particles may be prepared by
emulsion polymerization, emulsification (e.g., using any number of
conventional emulsifying agents), self-emulsification, dispersion,
and related methods in the art. The term "emulsion" generally
refers to a system of non-soluble liquid droplets within a
continuous liquid phase, while the term "dispersion" generally
refers to a system of solid particles in a liquid continuous phase.
Additionally, the term "emulsion" may also refer to a dispersion of
solid particles produced by emulsion polymerization. In this
patent, the terms "emulsion" and "dispersion" will be used
interchangeably to refer to a system of either solid particles or
liquid droplets in a continuous liquid phase.
[0075] The binder precursor may be dispersed in the continuous
phase by means of a surfactant adsorbed from the surrounding
continuous phase onto the surface of the binder precursor particles
or by means of a surfactant group grafted to or incorporated within
the backbone of the polymer chains comprising the binder precursor.
The term "external surfactant" refers to the former type of
surfactant (adsorbed to the surface of the particles) while the
term "internal surfactant" refers to the latter type of surfactant
(grafted to the backbone of the polymer).
[0076] A broad range of waterborne resin liquid compositions may be
used as a liquid composition of binder precursor 114. Acrylic
(co)-polymer emulsions, hydroxyl-functional acrylic copolymer
emulsions, styrene butadiene emulsions, polyurethane dispersions,
urethane-acrylic co-polymer dispersions, urethane-acrylic hybrid
dispersions, polyester dispersions, polyester urethane dispersions,
acrylic alkyd copolymer dispersions, epoxy dispersions, phenoxy
dispersions, epoxy novolac dispersions, acrylate-functional
radiation-curable resin dispersions, and amine-functional resin
dispersions are examples of binder precursor 114 compositions
suitable for embodiments of this invention.
[0077] Resin liquid compositions are characterized by the size and
morphology of the resin particles, the type of surfactants or
dispersants used to stabilize the resin particles, the quantity of
chemical reactive groups (i.e. acid number, epoxy number, hydroxyl
number, amine number), the molecular weight of the polymer inside
the resin particle, the film forming temperature, the glass
transition temperature of the polymer (Tg), the physical properties
of the coating after drying (hardness, impact resistance, %
elongation, modulus, tensile strength), their adhesion to various
substrates, etc.
[0078] In certain embodiments of this invention, two or more resin
compositions may be blended together to achieve a desirable set of
properties, for example hardness, Tg, or elongation.
[0079] In some embodiments the resin liquid composition (resin
dispersion) may have a core-shell structure. Copolymers designed
with a hard, glass like core and a soft rubbery shell will show a
lower minimum film forming temperature at a comparable coalescent
level than a physical blend of the same composition. In some
embodiments, the use of a hydrophobic core and hydrophilic shell
formed of alkaline soluble polymer chains modified with hydrophobic
components to make them relatively highly surface active allows the
production of surfactant free resin dispersion (AJP Buckmann et.
al., "Self-Crosslinking Polymeric Dispersants and their Use in
Emulsion Polymerization", presented at International Waterborne,
High Solids, and Powder Coatings Symposium, Symposium Sponsored by
the University of Southern Mississippi, Dept. of Polymer Science,
Feb. 6-8, 2002, New Orleans, La., USA).
[0080] Some examples include commercially available acrylic
dispersions (produced by emulsion polymerization) available from
HEXION (under the trademark AQUAMACT.TM.), LUBRIZOL ADVANCED
MATERIAL Inc. (under the trademarks CARBOSET.RTM. and HYCAR.RTM.),
DSM NEORESINS (under the trademark NEOCRYL.RTM.), REICHHOLD INC
(under the trademark AROLON.RTM.), BASF (under the trademark
ACRONAL.RTM.), and other manufacturers worldwide. Other examples
include polyurethane dispersions from BAYER (under the trademark
DISPERCOLL U), LUBRIZOL ADVANCED MATERIAL Inc. (under the
trademarks SANCURE.RTM.), DSM NEORESINS (under the trademark
NEOREZ.RTM.), REICHHOLD INC (under the trademark UROTUF.RTM.), BASF
(under the trademark LUPHEN.RTM.), and other manufacturers
worldwide.
[0081] Further examples include urethane-acrylic copolymer
dispersions and urethane-acrylic hybrid dispersions available from
AIR PRODUCTS (under the trademark HYBRIDUR.RTM.), DSM NEORESINS
(under the trademark NEOPAC.RTM.), and other manufacturers
worldwide.
[0082] Further still, suitable epoxy dispersions are available from
HEXION (under the trademark EPIREZ.TM.), and other manufacturers
worldwide. There are many types of epoxy dispersions such as for
example aqueous dispersion of a liquid Bisphenol A epoxy resin,
aqueous dispersion of a solid Bisphenol A epoxy resin, aqueous
dispersion of an epoxidized Bisphenol A novolac resin, aqueous
dispersion of a urethane modified epoxy resin, aqueous dispersion
of a butadiene-acrylonitrile modified epoxy resin, aqueous
dispersion of an epoxidized o-cresylic novolac resin.
[0083] Additionally, waterborne radiation curing resin dispersions
from suppliers such as SARTOMER, UCB RADCURE, or INCOREZ may be
suitable for this invention. These resin dispersions include
acrylate functional resins, which are dried prior to crosslinking
by such means as electron beam, UV, or other suitable methods.
[0084] In some embodiments the resin dispersion includes inorganic
particles, which are encapsulated in the resin particles or bound
to the resin particles. These inorganic particles may act as
fillers or abrasive particles. The introduction of these inorganic
particles may be made by the resin supplier during the emulsion
polymerization process. Examples of inorganic/organic latex
composites have been described in the scientific literature by
(Adeline Perro et al, "Synthesis of Hybrid Colloids through the
Growth of Polystyrene Latex Particles onto Methacryloxy methyl
triethoxysilane--Functionalized Silica Particles" MRS Symposium
Proceedings (2006).
Dispersants to Disperse the Abrasive Particles
[0085] In particular embodiments, the abrasive particles are
dispersed in a liquid carrier including water prior to the addition
of the binder precursor. The use of a dispersant is desired to
achieve abrasive particle dispersion, and prevent agglomeration and
settling. This is usually accomplished by one or both of two
mechanisms: electrostatic repulsion and/or stearic hindrance. A
wide range of dispersants may be used depending on the type and
size of the abrasive particles.
[0086] Anionic surfactants containing carboxylate, sulfonate,
sulfate, phosphate, and/or phosphonate groups may be used. For
example, 2-phosphonobutane 1,2,4 tricarboxylic acid tetrasodium
salt (PBTC-Na4), or 4,5 dihydroxy-m-benzenedisulfonic acid disodium
salt (TIRON) may be used to disperse fine alumina powders in water
as disclosed in patent EP 1529764.
[0087] Nonionic surfactants, such as the large number of widely
available adducts of ethylene oxide and block polymers of ethylene
oxide and propylene oxide, may be used to disperse the abrasive
particles. Nonyl phenol ethoxylate is typical example of such
surfactants.
[0088] Polymeric dispersants have a significantly higher molecular
weight than conventional dispersants. Polymeric dispersant contains
polymeric chains for stearic stability in solution, and pendant
anchoring groups, which absorb onto the surface of the abrasive
particles.
[0089] In some instances, anionic polymeric dispersants, with
molecular weight higher than 500 and an acid value higher than 0
such as PAA (polyacrylic acid), or PCA (copolymer of phosphono
& carboxylic acid), may be used to disperse the abrasive
particles.
[0090] Cationic surfactants or polymeric cationic dispersants may
also be used to disperse the abrasive particles, provided that the
resin dispersion is stabilized by nonionic surfactants or cationic
surfactants. If the dispersant used to disperse the abrasive
particles is not compatible with the resin dispersion, the abrasive
slurry may agglomerate.
[0091] In addition, surfactants (e.g., dispersants) may be used to
disperse other discontinuous phase in the slurry, including
fillers, pigments, and other additives not soluble in the
continuous phase.
Curing Agents, Cross-Linking Agents, and Hardeners
[0092] Optionally, curing agents, cross-linking agents, or
hardeners may be used to enhance binder properties by chemically
bonding polymer chains and forming a cross-linked network.
Appropriate curing agents for different resin systems are
well-known in the industry. Suitable curing agents include, but are
not limited to, the following, including combinations thereof:
metal ion crosslinkers, amines, peroxides, aziridines, isocyanates,
dicyandiamines, imidazoles, silanes, and photoinitiators.
[0093] In particular embodiments of this invention, a metal ion
crosslinker such as BACOTE 20 from MEI CHEMICALS may be used to
crosslink carboxyl or hydroxyl functional resins such as acrylic or
urethane dispersions. BACOTE 20 is an alkaline solution of
stabilized ammonium zirconium carbonate containing anionic
hydroxylated zirconium polymers. It is believed that BACOTE 20
functions by the generation of cationic zirconium resulting from
decomposition during drying.
[0094] In various embodiments of this invention, a water
dispersible aliphatic or aromatic polyisocyanate, such as DESMODUR
DN, DESMODUR DA-L, or BAYHYDRUR XP-7063 sold by BAYER, is combined
with a hydroxyl-functional acrylic copolymer emulsion, a
hydroxyl-functional polyurethane dispersion, or an aliphatic
polyester polyurethane dispersion.
[0095] In some embodiments of this invention, a micronized grade of
dicyandiamine such as DICYANEX.RTM. 1400B from AIR PRODUCTS, an
aqueous solution of 2-ethyl-4-methyl imidazole such as IMICURE
EMI-24 from AIR PRODUCTS, 2-methylimidazole powder from BASF, a
modified polyamidoamine adduct such as EPIKURE.TM. 8536-MY-60 from
HEXION, or a water dispersion of a modified polyamide adduct such
as EPIKURE.TM. 6870-W-53 from HEXION may be combined with a
waterborne epoxy dispersion.
[0096] In some embodiments of this invention, a silane such as
.beta.-(3,4-Epoxycyclohexyl) ethyltriethoxysilane available from
ACC SILICONES under the trademark SILQUEST 186 may be used to
crosslink carboxyl functional latexes, urethane dispersions,
urethane acrylic hybrid dispersions. The epoxy portion of the
molecule reacts with the matrix resin and the alkoxysilane portion
crosslinks after hydrolysis by condensation, forming siloxane
bonds.
[0097] In various embodiments of this invention, the use of two or
more crosslinking agents may be used. This may be desirable if two
chemically different resin dispersions are used such as for example
an acrylic emulsion together with an epoxy dispersion.
[0098] In specific embodiments, a photo-initiator such as DURACURE
1173 or IRGACURE 651 from CIBA is combined with a waterborne
radiation curable resin such as NEORAD NR-440 from DSM
NEORESIN.
Coalescing Agents and Co-Solvents
[0099] The continuous phase 116, in addition to water, may include
various coalescing agents and/or co-solvents to improve the coating
quality and help the discontinuous binder precursor particles to
coalesce into a continuous binder phase during drying. Hydrophobic
solvents such as ethylene glycol monobutyl ether, dipropylene
glycol n-butyl ether, tripropylene glycol n-butyl ether, and 2 2 4
trimethyl 1 3 pentanediol monoisobutyrate, and hydrophilic solvents
such as N-methylpyrrolidone (NMP) are often used.
Foam Control Agents
[0100] The continuous phase 116, in addition to water, may include
various additives, such as foam control agents. In this regard, the
presence of surfactants and chemical agitation under shear tends to
facilitate the production of the binder precursor liquid
composition and/or the abrasive slurry. However, this process may
generate macro foam and/or micro foam due to entrapped air.
Entrapped air/foam may cause various quality issues. Macro foam may
lead to coating defects such as non uniform appearance, streaks,
pinholes, while micro foam may generate micro pinholes in the
coating.
[0101] Waterborne abrasive slurries are generally more sensitive to
foam than solvent-based systems due to the presence of surfactants,
dispersants, and wetting agents (discussed in greater detail
hereinbelow) in the water. In solvent-based abrasive slurries the
organic solvent often acts as an anti-foaming agent. In waterborne
solutions, foam may be generated at each step of the production
process due to mechanical agitation: [0102] Air entrapment during
the mixing process to prepare the coating formulation. [0103] Air
entrapment during the coating process (described hereinbelow) when
the abrasive slurry 100 is applied on the backing 20 by roll
coating, knife over roll coating, spray coating, or when the
abrasive slurry is pumped or otherwise handled.
[0104] A wide variety of suitable foam control agents are available
for waterborne systems from many sources. Foam control agents are
sometimes called de-aerators, defoamers, or anti-foaming agents.
Quite often foam control agents are proprietary blends of various
ingredients such as water, mineral oils, fatty oils, vegetable
oils, silicone oils, glycols, alcohols, hydrophobic silica
derivatives, hydrophobic organic solids, surfactants, surface
active compounds, and the like. Foam control agents may also be
based on low molecular weight surfactants.
[0105] In particular embodiments of this invention, a combination
of two or more foam control agents may be used in the slurry base
and/or the resin blend.
Wetting Agents
[0106] Due to its high surface tension, water has an influence on
the quality of waterborne coatings. Wetting agents are surfactants
commonly used to enhance wetting and minimize coating defects such
as non-wets, fisheyes, craters, or dimples.
[0107] Many wetting agents such as hydrocarbon based surfactants,
silicone surfactants, non ionic fluoropolymer surfactants,
polyester-modified siloxanes, and monomeric surfactants may be used
to lower the surface tension of the abrasive slurry. In certain
embodiments of this invention, fluoro surfactants such as ZONYL and
CAPSTONE from DUPONT and NOVEC from 3M may be used to lower the
surface tension of the abrasive slurry.
Rheology Modifiers
[0108] In certain embodiments of this invention, the abrasive
slurry may be diluted by water or other solvents to adjust the
solids loading of the abrasive slurry and thus control the
thickness of the abrasive coating after drying. The use of rheology
modifiers may be desired to prevent settling of the abrasive
particles and to modify the rheology of the coating solution to
optimize the coating conditions.
[0109] Rheology modifiers may be classified into several
categories: [0110] Associative thickeners: These rheology modifiers
are usually water soluble polymers capped with water insoluble
hydrophobic groups. The primary thickening mechanisms is due to
intermolecular associations. This group includes the following:
[0111] HASE: hydrophobically modified alkali acrylic emulsions,
[0112] HEUR: hydrophobically modified ethylene oxide urethane
rheology modifiers, [0113] HEURASE: hybrid HASE/HEUR rheology
modifiers consisting of terpolymers of a carboxyl functional
monomer, a water insoluble monomer, and a urethane exothylate
monomer with a hydrophobic tail, [0114] HEAT: hydrophobically
modified ethoxylated aminoplast thickeners, and [0115] HMHEC:
hydrophobically hydroxyethyl cellulosic thickeners. [0116] Non
associative thickeners that interact with the water phase: This
group includes cellulosic thickeners, and acrylics. Cellulosic
thickeners include methyl cellulose (MC), hydroxyethyl cellulose
(HEC), ethyl hydroxyethyl cellulose (EHEC), hydroxypropyl cellulose
(HPC), hydroxypropyl cellulose (HPC), hydroxypropyl methyl
cellulose (HPMC), and hydrophobically hydroxyethyl cellulose
(HMHEC). Acrylics include acid or salt forms of water-soluble
acrylates, polyacrylic acids, and aramid pulp. [0117] Inorganic
thickeners, including clays, fumed silica, and overbased calcium
sulfonate gels. Clays include smectite clays such as bentonite,
hectorite, or montmorillonite, kaolin, mica, and attapulgite. Fumed
silica is available in a wide variety of forms including
hydrophobically treated versions using silanes, siloxanes, or
silazanes. [0118] Other rheology modifiers include castor oil
derivatives, carboxylic acid derivatives, polyamides, and
polysaccharides.
[0119] In certain embodiments of this invention, a low molecular
weight acrylic copolymer offered at 100% solids and soluble in
alkaline water sold by LUBRIZOL under the trademark CARBOSET.RTM.
515 is added to the abrasive slurry to promote dispersion,
leveling, flow and adhesion.
[0120] In certain embodiments of this invention, AQUAFLOW.RTM.
NLS-200, a hydrophobically modified polyacetal polyether from
HERCULES INC is added to the abrasive slurry to provide low to
medium shear viscosity along with excellent flow and leveling. A
nonanionic associative thickener AQUAFLOW.RTM. NHS-300 may also be
added to the abrasive slurry to increase high shear viscosity.
Other Additives
[0121] The abrasive slurry of this invention may further include
water soluble adhesion promoters such as silanes, zirconates or
titanate coupling agents, antistatic agents, inorganic pigments
such as TiO2, organic pigments, UV stabilizers, anti-oxidants,
grinding aids, biocides, fluorescent additives, etc. The amounts of
these materials are selected to provide the desired
performance.
[0122] The abrasive slurry may also include fillers. Fillers are
generally inorganic particles with a smaller particle size or a
lower hardness than the abrasive particles. They can be used to
modify the performance of the abrasive coating or reduce the raw
material cost.
Method of Manufacturing the Coated Abrasive Article for Lapping or
Polishing Applications
[0123] In particular embodiments of this invention, an abrasive
slurry base is prepared by adding the abrasive particles 12 to
liquid carrier, e.g., water, optionally with a dispersant, and/or a
foam control agent. A conventional milling procedure may then be
used to disperse the abrasive particles within the liquid carrier
to form an abrasive slurry base.
[0124] A binder precursor liquid composition may be prepared
separately, by mixing one or more resin compositions with one or
more of various additives such as anti-foaming agents, pigments,
water soluble adhesion promoters, co-solvent(s), and dilution
water. The binder precursor liquid composition as well as the
aforementioned additives may then be added to the abrasive slurry
base to form the abrasive slurry of the invention.
[0125] A representative process for producing an embodiment of a
coated abrasive product of the invention then includes the
following:
[0126] Providing a backing 20 having a surface configured for being
coated with an abrasive coating; [0127] Providing an abrasive
slurry 100 including a continuous liquid phase 116 (e.g., including
water), a first discontinuous phase including abrasive particles 12
dispersed in the continuous liquid phase, and a second
discontinuous phase including binder precursor particles 114
dispersed in the continuous liquid phase; [0128] Coating the
abrasive slurry onto at least one side of the backing 20 for
example by spray coating, roll coating, gravure coating, offset
gravure coating, reverse gravure coating, knife over roll coating,
slot die coating, or curtain coating; [0129] Removing the liquid
carrier in the continuous phase 116, e.g., by evaporation, e.g., by
drying in an oven; and [0130] Coalescing the binder precursor 114
of the discontinuous phase to form a solid continuous phase around
the abrasive particles 12; [0131] and optionally, curing or
crosslinking the binder using an energy source such as hot air,
e-beam, X-ray, UV light, infrared light, microwave, a combination
thereof, or any other crosslinking method known in the art.
[0132] For effective abrasive properties, the mass (weight) ratio
of abrasive particles to binder precursor should be between 0.07
and 11, more typically between 0.13 and 7, and even more preferably
between 0.20 and 5.5. The mass ratio of continuous phase to the sum
of all discontinuous phases (abrasive, binder precursor,
non-soluble additive, etc.) should be between 0.4 and 20, more
typically between 0.6 and 12, and even more preferably between 0.8
and 7. For effective abrasive properties, the slurry may be
configured so that the coating on the finished abrasive article may
include anywhere between 7% and 94% per weight of abrasive
particles, and more typically, from 12% to 88% per weight of
abrasive particles, and even more preferably from about 18% to
about 85% per weight of abrasive particles.
[0133] The coated abrasive article may then be converted into
various shapes such as discs, sheets, rolls, or other forms used in
the art, such as discs laminated to pressure-sensitive adhesives,
to meet customer requirements.
[0134] The following illustrative examples demonstrate certain
aspects and embodiments of the present invention, and are not
intended to limit the present invention to any one particular
embodiment or set of features.
EXAMPLES
TABLE-US-00001 [0135] TABLE Materials and Sources Material Name
Description Source E-600 High purity sub-micron Saint-Gobain
Ceramics calcined aluminum oxide & Plastics, Inc powder with
particle Worcester, MA size of 0.3 .mu.m. DISPERBYK 190 Dispersant
BYK USA Wallingford, CT Methylimidazole Imidazole epoxy curing PCI
Synthesis agent Newburyport, MA EPIKURE .TM. 3072 Curing agent for
epoxy Hexion Specialty resin Chemicals Houston, TEXAS Epirez
5003-W55 Waterborne epoxy Hexion Specialty dispersion Chemicals
Houston, TEXAS NEOPAC R9000 waterbased acrylic/urethane DSM
NEORESINS dispersion INC. Wilmington, MA NeoCryl .RTM. curing
Crosslinker DSM NEORESINS agent INC. Wilmington, MA 9 .mu.m
Aluminum Aluminum oxide abrasive Fujimi Corporation oxide particles
Tualatin, OR 30 .mu.m Aluminum Aluminum oxide abrasive Fujimi
Corporation oxide particles Tualatin, OR ACRYSOL ASE alkali
soluble, acrylic ROHM & HAAS thickener Philadelphia, PA Neocryl
A-662 Acrylic dispersion DSM NEORESINS INC. Wilmington, MA ZONYL
FSO Wetting agent DUPONT COMPANY Wilmington, DE NEOREZ R-9679
Urethane dispersion DSM NEORESINS INC. Wilmington, MA BYK-024 Foam
control agent BYK USA Wallingford, CT 9 .mu.m diamond Diamond
abrasives particles Warren Amplex Olyphant, PA TAMOL Dispersant
ROHM & HAAS Philadelphia, PA 3 .mu.m silicon carbide Silicon
carbide abrasive Fujimi Corporation particles Tualatin, OR 9 .mu.m
silicon carbide Silicon carbide abrasive Fujimi Corporation
particles Tualatin, OR
Example 1
Lapping Films with 0.3 Micron Aluminum Oxide Particles
Preparation of the Abrasive Slurry Base:
[0136] Approximately 7.5 kg of 3 mm diameter Yttria-stabilized
zirconia beads available from TOSOH was put into a one gallon
ball-milling jar. 1000 grams of an alumina powder (E-600) from
Saint-Gobain having a particle size around 0.3 micron, 560 grams of
de-ionized water, and 40 grams of DISPERBYK 190 were added to the
milling jar. The mixture was milled for 60 minutes.
Preparation of the Binder Precursor Liquid Composition 11:
[0137] 40 grams of EPIKURE.TM. 3072 and 0.67 grams of
Methylimidazole were added to 230 gram of resin Epirez 5003-W55
from Hexion. The mix was stirred for 10 minutes using a laboratory
mixer.
Preparation of the Abrasive Slurry 11:
[0138] 50 grams of the binder precursor liquid composition and 51
grams of the abrasive slurry base were combined into a 200-ml
beaker and stirred with a laboratory mixer for 5 minutes.
Preparation of the Binder Precursor Liquid Composition 12:
[0139] 5 grams of NEOCRYL curing agent was added to 100 grams of
Neopac R-9000 under agitation in a laboratory mixer.
Preparation of the Abrasive Slurry 12:
[0140] 50 grams of the binder precursor liquid composition 12 was
added to a 200-ml beaker and agitated with a laboratory mixer. 91
grams of the abrasive slurry base was added to the beaker and mixed
for 5 minutes.
Coated Abrasive Sample Preparation:
[0141] The abrasive slurries 11 & 12 were coated on a 3 mil
thick PET film using a #18 Meyer rod, and then dried and cured in
an oven at 300.degree. F. for 100 minutes.
Test Method:
[0142] A 3M Auto Polisher 6850A machine was modified to hold
1/8''-diameter rods in place of a fiber optic ferrule. 4'' discs of
the products to be tested were punched from laboratory drawdowns
and used as the test materials. 1/8'' acrylic rods were polished on
the various products. The weight loss of the rod was measured every
30 seconds. The downward pressure on the rod was 32 psi. The
surface speed of the rod on the test disc was 200 ft/minute.
[0143] The cumulative cut (milligrams) of the samples was measured
and compared to that provided by commercial samples from 3M (3M
Company). The following table summarizes the cumulative cut (in
milligrams) after 30, and 60 seconds of test. It shows that the
examples 11 and 12 with abrasive particles of 0.3 .mu.m have a
higher cut rate than not only the comparative commercial sample
with abrasive particles of 0.3 .mu.m, but also the comparative
commercial sample with abrasive particles of 0.5 .mu.m, which is
surprising.
TABLE-US-00002 Cut after Cut after Abrasive 30 seconds 60 seconds
3M 252X 0.5 .mu.m aluminum oxide 0.05 0.17 3M 261X 0.3 .mu.m
aluminum oxide 0.085 0.13 Example 11 E-600 (0.3 .mu.m 0.325 0.64
aluminum oxide) Example 12 E-600 (0.3 .mu.m 0.13 0.24 aluminum
oxide)
Example 2
9 Micron Aluminum Oxide Polishing Film
Preparation of the Abrasive Slurry Base:
[0144] Approximately 7.5 kg of 3 mm diameter Yttria-stabilized
zirconia beads available from TOSOH were put into a one gallon
ball-milling jar. 1000 grams of 9 .mu.m aluminum oxide abrasive
particles from Fujimi, 330 grams of de-ionized water, 13 gram of
ACRYSOL ASE, and 4.5 grams of a 10% ammonia solution were added to
the milling jar. The mixture was milled for 4 hours
Preparation of the Binder Precursor Liquid Composition:
[0145] 50 grams of NEOPAC R-9000 and 50 grams of Neocryl A-662 were
combined into a 200-ml beaker and stirred with a laboratory mixer
for 5 minutes.
Preparation of the Abrasive Slurry:
[0146] 100 grams of the abrasive slurry base was combined with 48
grams of the binder precursor liquid composition, 0.4 grams of
Zonyl FSO, 24 grams of water, 2 grams of ACRYSOL ASE, 2.2 grams of
a 10% ammonia solution, and 1.3 grams of NEOCRYL curing agent under
gentle agitation in a 200-ml beaker. The resulting abrasive slurry
was then mixed with a laboratory mixer for one hour.
Coated Abrasive Article Sample Preparation:
[0147] The abrasive slurry was coated on a 3 mil thick PET film
using a #30 Meyer rod, and then dried and cured in an oven at
300.degree. F. for 2 minutes.
[0148] The test method was the same as in example 1, except that
the 1/8'' acrylic rod was replaced by a 1/8'' 304 stainless steel
rod. The weight loss was measured every 4 minutes. The performance
of the new coated abrasive sample was compared to the comparative
sample: 3M 261.times.9 .mu.m.
[0149] The cumulative cut (in milligrams) data summarized in the
following table indicates that the polishing film sample #21 has a
higher polishing rate than the comparative sample with the same
grit size.
TABLE-US-00003 Cut Cut Cut Cut after 4 after 8 after 12 after 20
Abrasive minutes minutes minutes minutes Example 2 9 .mu.m aluminum
4.06 7.06 9.84 14.02 oxide 3M 261X 9 .mu.m aluminum 1.84 3.26 4.57
7.03 oxide
Example 3
30 Micron Aluminum Oxide Polishing Film
Preparation of the Abrasive Slurry Base:
[0150] Approximately 7.5 kg of 3 mm diameter Yttria-stabilized
zirconia beads available from TOSOH were put into a one gallon
ball-milling jar. 1000 grams of 30 .mu.m aluminum oxide abrasive
particles from Fujimi, 400 grams of de-ionized water, 8 grams of
ACRYSOL ASE, and 14 grams of a 10% ammonia solution were added to
the milling jar. The mixture was milled for 4 hours.
Preparation of the Binder Precursor Liquid Composition:
[0151] 44 grams of NEOREZ R-9679 was combined with 38 grams of
Neocryl A-662. The mix was stirred for 5 minutes using a laboratory
mixer.
Preparation of the Abrasive Slurry:
[0152] 100 grams of the abrasive slurry base was combined with 41
grams of the binder precursor liquid composition, 0.13 grams of
Zonyl FSO, 2.7 gram of water, 2.2 grams of ACRYSOL ASE, 3.4 grams
of a 10% ammonia solution, 1.0 grams of NEOCRYL CURING AGENT, and
0.38 grams of BYK-024 in a 200-ml beaker under gentle agitation.
The resulting abrasive slurry was then mixed with a laboratory
mixer for one hour.
Coated Abrasive Article Sample Preparation:
[0153] The abrasive slurry was coated on a 3 mil thick PET film
using a #42 Meyer rod, dried in an oven at 300.degree. F. for 2
minutes, and then post cured in an oven at 300.degree. F. for 12
hours.
[0154] The test method was the same as in example 1, except that
the 1/8'' acrylic rod was replaced by a 1/8'' 304 stainless steel
rod. The weight loss was measured every 4 minutes. The performance
of the new coated abrasive sample was compared to the comparative
sample: 3M 261.times.30 .mu.m.
[0155] The cumulative cut (in milligrams) data summarized in the
following table indicates that the polishing film sample #31 has a
higher polishing rate than the comparative sample with the same
grit size.
TABLE-US-00004 Cut Cut Cut Cut after 4 after 8 after 12 after 20
Abrasive minutes minutes minutes minutes Example 3 30 .mu.m
aluminum 15.47 27.95 39.40 59.12 oxide 3M 261X 30 .mu.m aluminum
6.98 13.00 17.97 27.05 oxide
Example 4
9 Micron Diamond Polishing Film
Preparation of the Abrasive Slurry Base:
[0156] Approximately 1 kg of 3 mm diameter Yttria-stabilized
zirconia beads available from TOSOH were put into a 500 cc
ball-milling jar. 100 grams of 9 .mu.m diamond abrasive particles
from Warren Amplex, 91 grams of de-ionized water, 0.5 grams of
DISPERBIK 190, 0.15 grams of BYK-024, 0.7 gram of ACRYSOL ASE, and
1.7 grams of a 10% ammonia solution were added to the milling jar.
The mixture was milled for 4 hours.
Preparation of the Binder Precursor Liquid Composition:
[0157] 76 grams of NEOREZ R-9679 were combined with 70 grams of
Neocryl A-662 The mix was stirred for 5 minutes using a laboratory
mixer.
Preparation of the Abrasive Slurry:
[0158] 100 grams of the abrasive slurry base were combined with 73
grams of the binder precursor liquid composition, 0.5 grams Zonyl
FSO, 80 grams water, 4.9 grams ACRYSOL ASE, 11.5 parts grams 10%
ammonia solution, and 2.0 grams NEOCRYL curing agent under gentle
agitation., and the resulting abrasive slurry was then mixed with a
laboratory mixer for one hour.
Coated Abrasive Article Sample Preparation:
[0159] The abrasive slurry was coated on a 3 mil thick PET film
using a #30 Meyer rod, dried in an oven at 300.degree. F. for 2
minutes, and then post cured in an oven at 300.degree. F. for 12
hours.
[0160] The test method was the same as in example 1, except that
the 1/8'' acrylic rod was replaced by a 1/8'' rod of zirconia
ceramic. The weight loss was measured after 8 minutes. The
performance of the new coated abrasive sample was compared to the
comparative samples: 3M 662-9 um from 3M and the comparative sample
Mipox-9 um from MIPDX (Nihon Micro Coating Co., Ltd). In addition
the surface finish of the polished surface was measured after the
test was completed.
[0161] The cumulative cut (in milligrams) and the surface finish
data are summarized in the following table. They indicate that the
polishing film sample #41 has surprisingly similar polishing rate,
but better surface finish (lower Ra and Rz) than the comparative
sample with a the same grit size.
TABLE-US-00005 Sample 4 - 3M 662 - Mipox - 9 .mu.m 9 .mu.m 9 .mu.m
Diamond Diamond diamond Cut after 8 minutes 4.03 4.01 3.91 Surface
finish Ra (.mu.m) 0.007 0.013 0.009 Surface finish Rz (.mu.m) 0.051
0.087 0.068
Example 5
3 Micron Silicon Carbide Lapping Film
Preparation of the Abrasive Slurry Base
[0162] Approximately 1 kg of 3 mm diameter Yttria-stabilized
zirconia beads available from TOSOH were put into a 500 cc
ball-milling jar. 90 grams of 3 .mu.m silicon carbide abrasive
particles from Fujimi, 41 grams de-ionized water, 2.7 grams
Disperbyk-190, 0.6 grams ACRYSOL ASE, and 0.08 grams 10% ammonia
solution were combined and ball milled for 4 hours.
Preparation of the Binder Precursor Liquid Composition
[0163] Epirez 5003-W55 was used as the binder precursor liquid
composition.
Preparation of the Abrasive Slurry
[0164] 53 grams of the abrasive slurry base was combined with 41
grams of the binder precursor liquid composition, 1.24 grams
Methylimidazole, 46 grams water, 0.2 grams Zonyl FSO, 0.45 grams
10% ammonia solution, and 2 grams ACRYSOL ASE under gentle
agitation. The resulting abrasive slurry was then mixed for one
hour.
Coated Abrasive Article Sample Preparation:
[0165] The abrasive slurry was coated on a 3 mil thick PET film
using a #30 Meyer rod, dried in an oven at 300.degree. F. for 2
minutes, and then post cured in an oven at 300.degree. F. for 12
hours.
[0166] The test method was the same as in example 1, except that
the 1/8'' acrylic rod was replaced by a 1/8'' rod of stainless
steel 304. The weight loss was measured every 2 minutes. The
performance of the new coated abrasive sample was compared to the
comparative sample: 3M 463.times.-3 .mu.m from 3M.
[0167] The cumulative cut (in milligrams) is summarized in the
following table. They indicate that the polishing film sample #51
has surprisingly a better polishing rate than the comparative
samples with a same grit size.
TABLE-US-00006 Cut after Cut after Cut after 2 minutes 4 minutes 6
minutes 3M 463X - 3 .mu.m silicon 1.2 1.6 1.9 carbide Example 5 - 3
.mu.m 1.9 2.8 3.5 silicon carbide
Example 6
9 Micron Silicon Carbide Polishing Film
Preparation of the Abrasive Slurry Base:
[0168] Approximately 1 kg of 3 mm diameter Yttria-stabilized
zirconia beads available from TOSOH were put into a 500 cc
ball-milling jar. 100 gram of 9 .mu.m silicon carbide abrasive
particles, 86 gram of de-ionized water, 2.8 gram of Tamol, and 0.12
gram of BYK-024 were added to the milling jar. The mixture was ball
milled for 4 hours.
Preparation of the Binder Precursor Liquid Composition
[0169] Epirez 5003-W55 was used as the binder precursor liquid
composition.
Preparation of the Abrasive Slurry:
[0170] 100 grams of the abrasive slurry base was combined with 39
grams of the binder precursor liquid composition, 185 grams water,
2.1 grams Zonyl FSO, 5.2 grams ACRYSOL ASE, 1.25 grams
Methylimidazole, and 0.09 grams BYK-024 under gentle agitation. The
resuling abrasive slurry was then mixed with a laboratory mixer for
one hour.
Coated Abrasive Article Sample Preparation:
[0171] The abrasive slurry was coated on a 3 mil thick PET film
using a #30 Meyer rod, dried in an oven at 300.degree. F. for 2
minutes, and then post cured in an oven at 300.degree. F. for 12
hours. The coated abrasive sample had an abrasive content of
approximately 67% per weight after curing.
[0172] The test method was the same as in example 1, except that
the 1/8'' acrylic rod was replaced by a 304 stainless steel 1/8''
rod. The weight loss was measured every 2 minutes. The performance
of the new coated abrasive sample was compared to the comparative
sample: 3M 461.times.-9 um from 3M.
[0173] The cumulative cut (in milligrams) is summarized in the
following table. They indicate that the polishing film sample #61
has a much higher polishing rate than the comparative sample.
TABLE-US-00007 Sample 6 - 9 .mu.m 3M 461X - 9 .mu.m Time Silicon
carbide Silicon carbide Cut after 2 minutes 6.28 2.06 Cut after 4
minutes 11.36 3.17 Cut after 6 minutes 15.68 4.11
[0174] It should be understood that any of the features described
with respect to one of the embodiments described herein may be
similarly applied to any of the other embodiments described herein
without departing from the scope of the present invention.
[0175] In the preceding specification, the invention has been
described with reference to specific exemplary embodiments for the
purposes of illustration and description. It is not intended to be
exhaustive or to limit the invention to the precise form disclosed.
Many modifications and variations are possible in light of this
disclosure. It is intended that the scope of the invention be
limited not by this detailed description, but rather by the claims
appended hereto.
* * * * *