U.S. patent application number 14/516345 was filed with the patent office on 2015-04-16 for amino resin treated backing material, coated abrasive articles incorporating same and process of making the same.
The applicant listed for this patent is Saint-Gobain Abrasifs, Saint-Gobain Abrasives, Inc.. Invention is credited to Chunjuan LIU.
Application Number | 20150101256 14/516345 |
Document ID | / |
Family ID | 52808457 |
Filed Date | 2015-04-16 |
United States Patent
Application |
20150101256 |
Kind Code |
A1 |
LIU; Chunjuan |
April 16, 2015 |
Amino Resin Treated Backing Material, Coated Abrasive Articles
Incorporating Same And Process Of Making The Same
Abstract
This invention relates an amino resin treated backing material
comprising a backing material impregnated with an amino resin
comprising an alkylated trimethylol melamine obtained by reaction
of trimethylol melamine with alkanol, coated abrasive article
comprising the same, and methods of making and using said amino
resin composition and coated abrasive articles. The claimed
processes and systems related to use and manufacturing of coated
abrasive articles are improved and cost effective.
Inventors: |
LIU; Chunjuan; (Shanghai,
CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Saint-Gobain Abrasives, Inc.
Saint-Gobain Abrasifs |
Worcester
Conflans-Sainte-Honorine |
MA |
US
FR |
|
|
Family ID: |
52808457 |
Appl. No.: |
14/516345 |
Filed: |
October 16, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61908612 |
Nov 25, 2013 |
|
|
|
Current U.S.
Class: |
51/298 ;
442/148 |
Current CPC
Class: |
Y10T 442/273 20150401;
B24D 11/00 20130101; B24D 11/02 20130101 |
Class at
Publication: |
51/298 ;
442/148 |
International
Class: |
B24D 11/02 20060101
B24D011/02; B24D 11/00 20060101 B24D011/00 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 16, 2013 |
CN |
201310485931.0 |
Claims
1. An amino resin treated backing material comprising: an amino
resin comprising a modified melamine formaldehyde resin having a
formula ##STR00009## wherein R1, R2, R3 each represents an
independent substituent selected from hydrogen and alkyl groups
having one to four carbon atoms; and a backing material, wherein
said backing material is impregnated with said amino resin.
2. An amino resin treated backing material comprising: an amino
resin comprising an alkylated trimethylol melamine obtained by
reaction of trimethylol melamine with alkanol; and a backing
material, wherein said backing material is impregnated with said
amino resin.
3. The amino resin treated backing material according to claim 2,
wherein the alkanol has 1 to 4 carbon atoms.
4. The amino resin treated backing material according to claim 3,
wherein the alkanol is methanol.
5. The amino resin treated backing material according to claim 1,
wherein the backing material comprises a polyester fabric.
6. The amino resin treated backing material according to claim 5,
wherein the backing material further comprises cotton, viscose,
polyamine, or combinations thereof.
7. The amino resin treated backing material according to claim 5,
wherein the polyester fabric comprises at least about 50 wt %
polyester.
8. The amino resin treated backing material according to claim 1,
wherein the amount of impregnation is equal to an add-on weight of
amino resin solution in a range from 10 g/m.sup.2 to 300 g/m.sup.2
of backing material.
9. The amino resin treated backing material according to claim 8,
wherein the add-on amino resin solution is cured at a temperature
of at least 95.degree. C.
10. The amino resin treated backing material according to claim 9,
wherein the add-on amino resin solution is cured at a temperature
of not greater than 175.degree. C.
11. The amino resin treated backing material according to claim 9,
wherein the add-on amino resin solution is at least partially
cured.
12. The amino resin treated backing material according to claim 11,
wherein the backing material is tack free.
13. The amino resin treated backing material according to claim 12,
wherein the tack free cure time is within a range of 30 to 300
seconds.
14. The amino resin treated backing material according to claim 11,
wherein the tensile strength factor is within a range of 1.0 to
2.5.
15. The amino resin treated backing material according to claim 11,
having an elongation rate factor within a range of not less than
0.3 to not greater than 1.0.
16. The amino resin treated backing material according to claim 12,
wherein the amino resin treated backing material is free of
bubbles.
17. The amino resin treated backing material according to claim 11,
having a body retention factor within a range of in a range of not
less than about 0.4 to not greater than about 1.0.
18. The amino resin treated backing material according to claim 11,
wherein the amino resin treated backing material has an edge
waviness of 3 mm or less.
19. A coated abrasive article comprising: an amino resin treated
backing material according to claim 1, and an abrasive layer
disposed on the amino resin treated backing material.
20. A coated abrasive article comprising: an amino resin treated
backing material impregnated with a cured modified melamine
formaldehyde resin having the formula: ##STR00010## wherein R1, R2,
R3 each represents an independent substituent selected from
hydrogen and alkyl groups having one to four carbon atoms; and an
abrasive layer disposed on the amino resin treated backing
material.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C.
.sctn.119(a) to, and incorporates herein by reference in its
entirety for all purposes, Chinese application CN201310485931.0,
filed Oct. 16, 2013, entitled "Amino Resin Treated Backing
Material, Coated Abrasive Articles Incorporating Same And Process
Of Making The Same", to Chunjuan LIU and which is assigned to the
current assignee hereof. This application also claims priority
under 35 U.S.C. .sctn.119(e) to, and incorporates herein by
reference in its entirety for all purposes, U.S. Patent Application
No. 61/908,612, filed Nov. 25, 2013, entitled "Amino Resin Treated
Backing Material, Coated Abrasive Articles Incorporating Same And
Process Of Making The Same, to Chunjuan LIU and which is assigned
to the current assignee hereof.
FIELD OF THE DISCLOSURE
[0002] The present invention relates to an amino resin treated
fabric composition, abrasive articles including the same, and
methods of making and using the amino resin treated fabric
composition and abrasive articles.
BACKGROUND
Description of the Related Art
[0003] Coated abrasive articles are used in a variety of industrial
and domestic applications. Coated abrasive articles typically
include a backing substrate, upon which is disposed an abrasive
layer. The abrasive layer is typically comprised of a "make coat"
of binder material that is applied as a layer disposed on one side
of the backing material, which then has abrasive particles disposed
upon the make coat. A "size coat" layer comprising a second binder
is then applied over the make coat and abrasive particles.
Optionally, coated abrasive articles can further comprise a
"supersize coat" covering the abrasive layer. A supersize coat
typically includes grinding aids and/or anti-loading materials.
[0004] Alternately, an abrasive layer can be a "slurry coat", where
abrasive particles are dispersed within the binder material to form
an abrasive slurry, and the slurry is then applied to the backing
material.
[0005] Coated abrasive articles can also comprise one or more
layers applied to a backing material prior to application of an
abrasive layer, including a "back size" layer (i.e., a coating
applied on the side of the backing material opposite the side
having the abrasive layer), a pre-size layer, a tie layer (i.e., a
coating between the abrasive layer and the major surface of the
backing to which the abrasive layer is secured), and/or a saturant.
Optionally, the backing may further comprise a sub-size treatment.
Sub size is similar to a saturated except that it is applied to a
previously treated backing.
[0006] Conventional backing layers typically include various types
of resins (e.g., polyvinyl alcohol, starch, latex, phenolic resins,
and urea formaldehyde resins); however, all of these treatment
suffer from various limitations, such as inadequate adhesion
between the various layers, poor heat resistance, poor wear
resistance, susceptibility to degradation due to the presence of
solvents or elevated curing temperatures. Further, conventional
backing treatments can emit various volatile compounds that can
impart undesirable porosity to the abrasive layer, act as
contaminants, or interfere with curing of the abrasive layer.
[0007] Manufactures are sensitive to reducing costs while still
seeking to maintain or improve abrasive performance, thus there
continues to be a demand for improved and cost effective processes
and systems related to use and manufacturing of coated abrasive
articles.
BRIEF DESCRIPTION
[0008] An embodiment provides an amino resin treated backing
material, comprising:
an amino resin comprising a modified melamine formaldehyde resin
having a formula
##STR00001##
wherein R.sub.1, R.sub.2, R.sub.3 each represents an independent
substituent selected from hydrogen and alkyl groups having one to
four carbon atoms; and a backing material, wherein said backing
material is impregnated with said amino resin.
[0009] An embodiment also provides another amino resin treated
backing material, comprising:
an amino resin comprising an alkylated trimethylol melamine
obtained by reaction of trimethylol melamine with alkanol; and a
backing material, wherein said backing material is impregnated with
said amino resin.
[0010] An embodiment also provides a coated abrasive article
comprising:
an amino resin treated backing material according to claim 1 or 2,
and an abrasive layer disposed on the amino resin treated backing
material.
[0011] An embodiment provides another coated abrasive article
comprising:
an amino resin treated backing material impregnated with a cured
modified melamine formaldehyde resin having the formula:
##STR00002##
wherein R.sub.1, R.sub.2, R.sub.3 each represents an independent
substituent selected from hydrogen and alkyl groups having one to
four carbon atoms; and an abrasive layer disposed on the amino
resin treated backing material.
[0012] An embodiment further provides a process of making an amino
resin treated backing material comprising: mixing water, catalyst,
and a modified melamine formaldehyde resin to form an amino resin
solution, saturating a backing material with said amino resin
solution to form a saturated backing material; and curing said
saturated backing material to form the amino resin treated backing
material, wherein the modified melamine formaldehyde resin has the
formula
##STR00003##
wherein R.sub.1, R.sub.2, R.sub.3 each represents an independent
substituent selected from a hydrogen or an alkyl group having one
to four carbon atoms.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present disclosure may be better understood, and its
numerous features and advantages made apparent to those skilled in
the art by referencing the accompanying drawings.
[0014] FIG. 1 is an illustration of a flowchart of an embodiment of
a method of making a treated fabric backing according to the
present invention.
[0015] FIG. 2 is an illustration of a schematic of an embodiment of
a method of making a treated backing fabric according to the
present invention.
[0016] FIG. 3 is an illustration of a cross-section of an
embodiment of a coated abrasive according to the present
invention.
[0017] FIG. 4 is an illustration of a cross-section of an
embodiment of a coated abrasive according to the present
invention.
[0018] FIG. 5 is a graph comparing the storage modulus (G') of
amino resin solution samples with catalyst and without catalyst as
a function of temperature.
[0019] FIG. 6 is a graph of body retention test data of inventive
embodiments of amino resin treated polyester specimens.
[0020] FIG. 7 is a graph of body retention test data of comparative
phenolic resin treated polyester specimens.
[0021] FIG. 8 is a photograph of the edge of an amino resin treated
fabric embodiment showing the fabric edge is smooth and
straight.
[0022] FIG. 9 is a photograph of the edge of a comparative phenolic
resin treated fabric showing the fabric edge is puckered and
curved.
[0023] The use of the same reference symbols in different drawings
indicates similar or identical items.
DETAILED DESCRIPTION
[0024] The following description, in combination with the figures,
is provided to assist in understanding the teachings disclosed
herein. The following discussion will focus on specific
implementations and embodiments of the teachings. This focus is
provided to assist in describing the teachings and should not be
interpreted as a limitation on the scope or applicability of the
teachings.
[0025] The term "averaged," when referring to a value, is intended
to mean an average, a geometric mean, or a median value. As used
herein, the terms "comprises," "comprising," "includes,"
"including," "has," "having," or any other variation thereof, are
intended to cover a non-exclusive inclusion. For example, a
process, method, article, or apparatus that comprises a list of
features is not necessarily limited only to those features but can
include other features not expressly listed or inherent to such
process, method, article, or apparatus. As used herein, the phrase
"consists essentially of" or "consisting essentially of" means that
the subject that the phrase describes does not include any other
components that substantially affect the property of the
subject.
[0026] Further, unless expressly stated to the contrary, "or"
refers to an inclusive- or and not to an exclusive- or. For
example, a condition A or B is satisfied by any one of the
following: A is true (or present) and B is false (or not present),
A is false (or not present) and B is true (or present), and both A
and B are true (or present).
[0027] The use of "a" or "an" is employed to describe elements and
components described herein. This is done merely for convenience
and to give a general sense of the scope of the invention. This
description should be read to include one or at least one and the
singular also includes the plural, or vice versa, unless it is
clear that it is meant otherwise.
[0028] Further, references to values stated in ranges include each
and every value within that range. When the terms "about" or
"approximately" precede a numerical value, such as when describing
a numerical range, it is intended that the exact numerical value is
also included. For example, a numerical range beginning at "about
25" is intended to also include a range that begins at exactly 25.
Moreover, it will be appreciated that references to values stated
as "at least about," "greater than," "less than," or "not greater
than" can include a range of any minimum or maximum value noted
therein.
[0029] As used herein, the phrase "average particle diameter" can
be reference to an average, mean, or median particle diameter, also
commonly referred to in the art as D50.
[0030] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. The
materials, methods, and examples are illustrative only and not
intended to be limiting. To the extent not described herein, many
details regarding specific materials and processing acts are
conventional and can be found in textbooks and other sources within
the coated abrasive arts.
[0031] Referring now to the figures, FIG. 1 illustrates a flow
diagram of an embodiment of a process for making an amino resin
treated backing material. During step 101, mixing of an amino
resin, a catalyst, and water occurs to form an amino resin
solution. During step 103, a backing material is saturated (also
referred to herein as "impregnated") with the amino resin solution.
Optionally, adjusting the amount of saturation (i.e., adjusting the
amount of add on amino resin weight) can occur in step 105. During
step 107, curing, at least partially to fully, of the saturated
backing material (i.e., curing at least partially to fully the add
on amino resin) occurs to form an amino resin treated backing
material.
[0032] Referring to FIG. 2, a process 200 for making an amino resin
treated backing material is shown. A backing material 201 can be
immersed in an amino resin solution 203. The saturated backing
material 205 can be manipulated to adjust the amount of saturation
of the backing material (i.e., adjust the amount of amino resin
that the backing material contains), such as by squeezing the
saturated backing material between a pair of rollers 207. The
saturation-adjusted pre-cured backing material 209 can be directed
into an oven 211 (such as a multi-stage oven) to at least partially
to fully cure the amino resin and form an amino resin treated
backing material 215. The amino resin treated backing material can
be stored for later use, such as by winding into a roll 217, or
alternatively, be subjected to further processing steps to form a
coated abrasive article.
Preparation of Amino Resin Solution
[0033] All the ingredients of the amino resin solution are
thoroughly mixed together. Mixing can be conducted using high shear
conditions, moderate shear conditions, low shear conditions, or
combinations thereof. Typically, mixing occurs until the
ingredients are thoroughly mixed.
[0034] During mixing of the amino resin solution ingredients, the
ingredients may be added to the amino resin solution one by one, in
batches, or all at once. Typically the ingredients are added one by
one to the amino resin solution. If the ingredients are added one
by one or in batches, the amino resin solution can be agitated for
a period of time until the ingredient has sufficiently mixed into
the amino resin solution. Typical agitation times range from about
1 minute to about 2 hours, depending on the ingredient or
ingredients being added to the amino resin solution.
[0035] The temperature of the amino resin solution can be adjusted
if desired during mixing. The temperature of the amino resin
solution during mixing can be in a range of about 15.degree. C. to
about 45.degree. C., such as about 20.degree. C. to about
25.degree. C. The pH of the amino resin solution can be adjusted
during mixing. The pH can be adjusted by the addition of an acid, a
base, a buffer solution, or a combination thereof if desired. The
pH of the amino acid resin solution is typically close to neutral,
but can be acidic or basic, such as in a range of about 3 pH to
about 9 pH.
[0036] The amount of the amino resin, catalyst, and water can be
adjusted to control the viscosity of the amino resin solution. The
viscosity of the amino resin solution can be monitored as it is
being prepared. In an embodiment, the viscosity of the amino resin
solution is adjusted to be within a particular range. In an
embodiment, the viscosity of the amino resin solution is in a range
of about 10 cps to about 200 cps prior to addition of the catalyst
to the amino resin solution. After the addition of the catalyst,
the amino resin solution can have a viscosity in a range of about
10 cps to about 450 cps.
[0037] In an embodiment, the amino resin solution has a composition
that can include:
from about 30 wt % to about 94 wt % amino resin; from about 0.05 wt
% to about 5 wt % catalyst; and the remainder is water, wherein the
percentages are based on a total weight of the amino resin solution
and all the percentages of the ingredients add up to 100 wt %.
Optionally, from about 0.1 wt % to about 5 wt % of additives can
also be added to the amino resin solution. If one or more additives
is included, the amount of water can be adjusted so that the total
amounts of the ingredients in the amino resin solution add up to
100 wt %.
[0038] In an embodiment, the total amount of amino resin in the
amino resin solution can be not less than about 30 wt %, not less
than about 35 wt %, not less than about 40 wt %, not less than
about 45 wt %, not less than about 50 wt %, not less than about 55
wt %, not less than about 60 wt %, not less than about 65 wt %, not
less than about 70 wt %, or not less than about 75 wt %. In another
embodiment, the amount of amino resin in the amino resin solution
can be not greater than about 94 wt %, not greater than about 90 wt
%, not greater than about 85 wt %, or not greater than about 80 wt
%. The amount of amino resin in the amino resin solution can be
within a range comprising any pair of the previous upper and lower
limits. In a particular embodiment, the amount of amino resin
included in the amino resin solution can be in the range of not
less than about 50 wt % to not greater than about 94 wt %.
[0039] In an embodiment, the total amount of catalyst in the amino
resin solution can be not less than about 0.05 wt %, not less than
about 0.075 wt %, not less than about 0.1 wt %, not less than about
0.2 wt %, not less than about 0.3 wt %, not less than about 0.4 wt
%, not less than about 0.5 wt %, not less than about 0.6 wt %, not
less than about 0.7 wt %, not less than about 0.8 wt %, not less
than about 0.9 wt %, or not less than about 1.0 wt %. In another
embodiment, the amount of catalyst in the amino resin solution can
be not greater than about 5 wt %, not greater than about 4 wt %,
not greater than about 3 wt %, not greater than about 2.5 wt %, not
greater than about 2.25 wt %, or not greater than about 2.0 wt %.
The amount of catalyst in the amino resin solution can be within a
range comprising any pair of the previous upper and lower limits.
In a particular embodiment, the amount of catalyst included in the
amino resin solution can be in the range of not less than about 0.8
wt % to not greater than about 2.2 wt %.
[0040] The amount of water in the amino resin solution can be
adjusted as desired. In an embodiment, the total amount of water in
the amino resin solution can be not less than about 1 wt %, not
less than about 5 wt %, not less than about 10 wt %, or not less
than about 15 wt %. In another embodiment, the amount of water in
the amino resin solution can be not greater than about 70 wt %, not
greater than about 60 wt %, not greater than about 50 wt %, not
greater than about 40 wt %, not greater than about 30 wt %, or not
greater than about 20 wt %. The amount of water in the amino resin
solution can be within a range comprising any pair of the previous
upper and lower limits. In a particular embodiment, the amount of
water included in the amino resin solution can be in the range of
not less than about 1 wt % to not greater than about 70 wt %.
[0041] In an embodiment, the amino resin solution can have a weight
ratio of catalyst to amino resin in a range from about 1:1000 to
about 1:16. In an embodiment, the weight ratio of catalyst to amino
resin can be at least about 1:1000, such as at least about 1:800,
at least about 1:500, at least about 1:200, at least about 1:100,
at least about 1:90, at least about 1:85, or even at least about
1:80. In an embodiment, the weight ratio of catalyst to amino resin
can be not greater than about 1:16, such as not greater than about
1:20, not greater than about 1:25, or not greater than about 1:30.
The amount of water in the amino resin solution can be within a
range comprising any pair of the previous upper and lower limits.
In an embodiment, the amino resin solution can have a weight ratio
of catalyst to amino resin in a range from about 1:800 to about
1:32.
Amino Resin
[0042] Suitable amino resins for use in the amino resin solution
can include modified or blocked melamine formaldehyde resins. In an
embodiment, the amino resin is an alkylated trimethylol melamine
resin (hereinafter "ATMM"). In an embodiment, the amino resin can
have formula
##STR00004##
wherein R1, R2, R3 each represents an independent substituent
selected from a hydrogen or an alkyl group having one to four
carbon atoms to form an amino resin solution.
[0043] In an embodiment, R1, R2, and R3 are equal hydrogen. In
another embodiment, R1, R2, and R3 are equal to a methyl group. In
another embodiment, R1, R2, and R3 are equal to an ethyl group. In
another embodiment, R1, R2, and R3 are equal to an n-propyl group.
In another embodiment, R1, R2, and R3 are equal to an isopropyl
group. In another embodiment, R1, R2, and R3 are equal to an
n-butyl group. In another embodiment, R1, R2, and R3 are equal to a
2-butyl group. In another embodiment, R1, R2, and R3 are equal to
an isobutyl group. R1, R2, and R3 can be the same, different, or
combinations thereof.
[0044] It will be appreciated that the alkylated trimethylol
melamine can be obtained by reaction of (i.e., is the reaction
product of) a trimethylol melamine with an alkanol. In an
embodiment, the alkanol can include 1 to 4 carbon atoms. In a
specific embodiment, the alkanol is a methanol. The reaction can be
conducted in an aqueous solution.
[0045] In a specific embodiment, the modified melamine formaldehyde
resin is 1,3,5-Triazine-2,4,6triamine,
N2,N4,N6-tris(methoxymethyl), chemical structure shown below.
##STR00005##
Catalyst
[0046] The amino resin solution can include a catalyst. The
catalyst can be a single compound or a mixture of compounds. In an
embodiment, suitable catalyst compounds include substituted or
unsubstituted alkyl acids, or combinations thereof. In another
embodiment, a catalyst can include, or be selected from, alkyl
phosphoric acids, alkyl sulfonic acids, or combinations thereof. In
an embodiment, a catalyst can comprise phosphoric acid, alkyl acid
phosphates, amine blocked alkyl benzene sulfonic acid, hydrochloric
acid, naphthalene sulfonic acid, alkyl phenyl phosphate, alkyl
benzene sulfonic acid, blocked para-toluene sulfonic acid(p-TSA),
or a combination thereof.
Water
[0047] In accordance with an embodiment, the amino resin solution
can include water. Water can be tap water, distilled water,
deionized water, or combinations thereof.
Saturating the Backing Material
[0048] A backing material can be saturated with amino resin
solution (also referred to herein as being "impregnated" with amino
resin solution) by any suitable manner that applies a sufficient
amount of amino resin solution so that the backing material becomes
thoroughly soaked with the amino resin solution. In an embodiment,
saturation can be accomplished by dipping, spraying, submerging,
coating, or washing the backing material with or in the amino resin
solution, or combinations thereof. The saturation can occur as a
single step or multiple steps, such as multiple dipping or multiple
spraying of the backing material with the amino resin solution. In
a specific embodiment, the backing material is dipped into an amino
resin solution. In another embodiment a backing material is sprayed
with an amino resin solution.
Amount of Saturation--Add-on Weight
[0049] The amount of amino resin solution that saturates the
backing material (i.e, the amount of amino resin solution that
adheres to and/or is absorbed by the backing material) is also
known as the "add-on" weight of the amino resin solution. The
amount of saturation can be expressed as a percentage of the
original weight of the backing material. For example, if the dry
backing material weighs 100 g/m.sup.2 and after saturation weighs
150 g/m.sup.2, the cloth would be 50% saturated. Alternatively, the
amount of saturation can be expressed as an amount of add-on weight
of the amino resin solution. For example, if the dry backing
material weighs 100 g/m.sup.2 and after saturation weighs 150
g/m.sup.2, the amount of saturation would be expressed as 50
g/m.sup.2 of add-on weight of amino resin solution. The amount of
saturation can also be expressed as a combination of percentage of
the original weight of the backing material and add-on weight.
[0050] In an embodiment, the amount of saturation of the backing
material can be in a range of not less than about 1 wt %, not less
than about 2.5 wt %, not less than about 5 wt %, not less than
about 10 wt %, not less than about 12.5 wt %, not less than about
15 wt %, not less than about 20 wt %, not less than about 25 wt %,
not less than about 30 wt %, or not less than about 35 wt %. In
another embodiment, the amount of saturation of the backing
material can be not greater than about 500 wt %, not greater than
about 400 wt %, not greater than about 300 wt %, not greater than
about 200 wt %, not greater than about 100 wt %, not greater than
about 90 wt %, not greater than about 80 wt %, not greater than
about 70 wt %, not greater than about 60 wt %, not greater than
about 50 wt %, or not greater than about 40 wt %. The amount of
saturation of the backing material can be within a range comprising
any pair of the previous upper and lower limits. In a particular
embodiment, the amount of saturation of the backing material can be
in the range of not less than about 1 wt % to not greater than
about 500 wt %.
[0051] In an embodiment, the amount of saturation of the backing
material can be in a range of about 10 g/m.sup.2 to about 300
g/m.sup.2 of backing material. In an embodiment, the amount of
saturation of the backing material (i.e., wet add-on amino resin
solution weight) can be at least about 10 g/m.sup.2, such as at
least about 50 g/m.sup.2, at least about 100 g/m.sup.2, at least
about 150 g/m.sup.2, at least about 200 g/m.sup.2, or at least
about 250 g/m.sup.2. In an embodiment, the amount of saturation of
the backing material can be in a range of not greater than about
300 g/m.sup.2, such as not greater than about 250 g/m.sup.2, not
greater than about 200 g/m.sup.2, not greater than about 150
g/m.sup.2, not greater than about 100 g/m.sup.2, or not greater
than about 50 g/m.sup.2. The amount of saturation of the backing
material can be within a range comprising any pair of the previous
upper and lower limits. In a particular embodiment, the amount of
saturation of the backing material can be in the range of not less
than about 10 g/m.sup.2 to about 300 g/m.sup.2.
Adjusting Saturation
[0052] As illustrated in FIG. 1 and FIG. 2, the amount of amino
resin solution saturation of the backing material can be adjusted.
Adjusting the saturation of the amino resin solution can be
accomplished by any method or mechanism that does not overly
degrade the backing material and that re-applies or removes a
desired amount of amino resin solution so that the backing material
has a desired amount of saturation. Adjusting the amount of amino
resin solution can be accomplished in a single or multiple steps.
Adjusting the amount of amino resin solution can include pressing,
squeezing, brushing, squeegeeing, blowing, dabbing, blotting,
shaking, combinations thereof, or the like. In a specific
embodiment, the saturated backing material can be squeezed, such as
between a pair of rollers to adjust the saturation of the saturated
backing material.
Backing Material
[0053] The backing material can be organic material, inorganic
material, natural material, synthetic material, or combinations
thereof. The backing can be flexible or rigid. The backing material
can be made of a single material or combination of various
materials. In an embodiment, a particular backing material is a
polyester material. In an embodiment, a backing material is or
includes a polyester fabric. A polyester fabric can be a fabric
blend that includes polyester fibers and one or more other types of
fibers. In an embodiment, the backing material can be a cloth
(e.g., cloth made from fibers or yarns comprising polyester, nylon,
silk, cellulose fiber, cotton, viscose, polyamide, polyamines,
poly-cotton, rayon, or combinations thereof) In an embodiment, the
backing material can be a composite backing material that comprises
a polyester material and one or more other backing materials, such
as paper; vulcanized paper; vulcanized rubber; vulcanized fiber;
nonwoven materials, thermoplastic film, such as a polyethylene
terephthalate (PET) film, a network of fibers, for example a mat, a
felt, a fabric or a knit of natural or synthetic fibers, including
mineral fibers, glass fibers, polymer fibers, plant fibers, or
combinations thereof; or any treated version thereof. Cloth backing
materials can be woven, stitch bonded, combed, carded, filament, or
any combination thereof. The backing material can be a finished
cloth, unfinished cloth (i.e. "grey cloth"), or a combination
thereof. In a particular embodiment, the backing material is an
unfinished polyester fabric. In a particular embodiment, the
backing material is a woven polyester fabric. In another specific
embodiment, the backing material is a polyester blend fabric of 90%
polyester and 10% cotton fibers.
[0054] In accordance with an embodiment, the backing material prior
to saturation can include at least about 50 wt % polyester, such as
at least about 60 wt % polyester, at least about 70 wt % polyester,
at least about 75 wt % polyester, at least about 80 wt % polyester,
at least about 90 wt % polyester, or even at least about 95 wt %
polyester. In an embodiment, the backing material prior to
saturation can include not greater than about 95 wt % polyester,
such as not greater than about 90 wt % polyester, not greater than
about 80 wt % polyester, not greater than about 75 wt % polyester,
not greater than about 70 wt % polyester, or even not greater than
about 60 wt % polyester, not greater than about 50 wt % polyester.
The amount of backing material prior to saturation can be within a
range comprising any pair of the previous upper and lower
limits.
Drying/Curing
[0055] After saturation of the backing material with amino resin
solution, and any optional adjustment of the amount of saturation
of the backing material, the saturated or saturation adjusted
pre-cure backing material can undergo curing to form completed
amino resin treated backing material. The completed amino resin
treated backing material is impregnated with cured amino resin.
Curing can be conducted in a single step or multiple steps. Curing
can be accomplished by exposure to a heat source, such as a heating
tunnel or oven, including a multi stage oven, or the like.
Alternative heating sources can include exposure to infrared
radiation lamps, or the like.
[0056] In an embodiment, the saturated backing material (or the
adjusted saturation backing material) is cured at a particular
temperature. The add-on amino resin saturating the backing material
is cured. In an embodiment, the curing temperature is at least
about 95.degree. C., such as at least about 100.degree. C., such as
at least about 110.degree. C., or at least about 125.degree. C. In
an embodiment, the curing temperature is not greater than about
175.degree. C., such at not greater than about 170.degree. C., not
greater than about 165.degree. C., not greater than about
160.degree. C., not greater than about 155.degree. C., or not
greater than about 150.degree. C. The curing temperature of the
backing material can be within a range comprising any pair of the
previous upper and lower limits. In a particular embodiment, the
curing temperature can be in the range of not less than 100.degree.
C. to about 150.degree. C.
[0057] In accordance with an embodiment, the saturated backing
material (or the adjusted saturation backing material) (i.e., the
add-on amino resin solution saturating the backing material) can be
cured to a particular degree. In an embodiment, the add-on amino
resin solution saturating the backing material can be partially
cured or completely cured. In a particular embodiment, the add-on
amino resin solution can be cured to a degree that the previously
saturated fabric is rendered tack free (i.e., not tacky, does not
stick to fingers). In a specific embodiment, the saturated backing
material is partially cured and not tacky to the touch. In another
specific embodiment, the saturated backing material is completely
cured and not tacky to the touch. The amino resin treated material
that is impregnated with partially cured or completely cured amino
resin is not tacky to the touch.
[0058] In an embodiment, the backing material may be cured to a
tack-free degree within a particular amount of time. In an
embodiment, the backing material may be cured to a tack-free degree
within at least about 30 seconds, such as at least about 45
seconds, at least about 60 seconds, at least about 90 seconds, at
least about 120 seconds, at least about 150 seconds, at least about
180 seconds, at least about 210 seconds, at least about 240
seconds, or even at least about 270 seconds. In an embodiment, the
backing material may be cured to a tack-free degree within not
greater than about 300 seconds, such as not greater than about 270
seconds, not greater than about 240 seconds, not greater than about
210 seconds, not greater than about 180 seconds, not greater than
about 150 seconds, not greater than about 120 seconds, not greater
than about 90 seconds, not greater than about 60 seconds, or even
not greater than about 45 seconds. The backing material can be
cured to a tack-free degree within a particular amount of time
within a range comprising any pair of the previous upper and lower
limits. In a particular embodiment, the backing material can be
cured to a tack-free degree within a range of not less than 30
seconds to not greater than about 300 seconds.
[0059] It will be appreciated that the inventive saturated backing
material embodiments can surprisingly and beneficially be cured at
lower temperatures (such as approximately 50.degree. C. lower) to a
tack-free state and even to a completely cured state compared to
conventional backing treatments. The reduction in curing
temperature produces a significant reduction in energy consumed,
particularly over the extended curing times that are typically
employed to assure complete curing of coated abrasive articles
(e.g., 20 hours). Further, the lower curing temperatures avoid
thermal degradation of the backing material, thus helping prevent
premature failure of coated abrasive articles that incorporate the
amino resin treated coated abrasive.
[0060] Further, it is expected that the amino resin treated backing
material impregnated with cured amino resin exhibits beneficial
physical and abrasive performance properties.
Features of the Article
[0061] An amino resin treated backing material formed in accordance
with embodiments herein may enjoy particular beneficial features.
In accordance with an embodiment, the amino resin treated backing
material can have a particular tensile strength factor. The tensile
strength factor can be defined as a ratio of the tensile strength
of the amino resin treated backing material to the tensile strength
of a conventionally treated backing material or an untreated
backing material. Alternatively, the tensile strength factor can be
defined as a percent increase compared to the tensile strength of a
conventionally treated backing material or an untreated backing
material.
[0062] In an embodiment, the tensile strength factor can be at
least about 1.0, such as at least about 1.05, at least about 1.1,
at least about 1.15, or at least about 1.2 of a conventionally
treated backing material or an untreated backing material. In an
embodiment, the tensile strength factor can be not greater than
about 2.5, such as not greater than about 2.25, not greater than
about 2.0, not greater than about 1.75, not greater than about 1.5,
or not greater than about 1.4 of a conventionally treated backing
material or an untreated backing material. The tensile strength
factor of the amino resin treated backing material can be within a
range comprising any pair of the previous upper and lower limits.
In a particular embodiment, the tensile strength factor of the
amino resin treated backing material can be in a range of not less
than 1.0 to not greater than about 2.5 of a conventionally treated
backing material or an untreated backing material.
[0063] In an embodiment, the tensile strength factor can be at
least about a 2.5% increase, such as at least about a 5% increase,
at least about a 7.5% increase, at least about a 10% increase, or
at least about a 12.5% increase in tensile strength of a
conventionally treated backing material or an untreated backing
material. In an embodiment, the tensile strength factor can be not
greater than about a 100% increase, such as not greater than about
a 75% increase, not greater than about a 50% increase, or not
greater than about a 25% increase in tensile strength of a
conventionally treated backing material or an untreated backing
material. The tensile strength factor of the amino resin treated
backing material can be within a range comprising any pair of the
previous upper and lower limits. In a particular embodiment, the
tensile strength factor of the amino resin treated backing material
can be in a range of not less than about a 2.5% increase to not
greater than about a 100% increase of a conventionally treated
backing material or an untreated backing material.
[0064] In accordance with an embodiment, the amino resin treated
backing material can have a particular elongation rate factor. The
elongation rate factor can be defined as a ratio of the elongation
rate of the amino resin treated backing material to the elongation
rate of a conventionally treated backing material or an untreated
backing material (lower elongation rate factor is better).
Alternatively, the elongation factor can be defined as a percent
decrease compared to the elongation rate of a conventionally
treated backing material or an untreated backing material. In
accordance with an embodiment, the amino resin treated backing
material can have a particular elongation factor that can be
defined as a ratio of an elongation rate at 600 N of an amino resin
treated backing material to a conventionally treated backing
material or an untreated backing material. In an embodiment, the
elongation factor can be not greater than 1.0, such as not greater
than 0.95, not greater than 0.9, not greater than 0.85, not greater
than 0.80, or not greater than 0.75. In an embodiment, the
elongation factor can be not less than about 0.5, such as not less
than about 0.4, or not less than about 0.3. The elongation rate
factor of the amino resin treated backing material can be within a
range comprising any pair of the previous upper and lower limits.
In a particular embodiment, the elongation rate factor of the amino
resin treated backing material can be in a range of not greater
than about 1.0 to not less than about 0.3 of a conventionally
treated backing material or an untreated backing material.
[0065] In an embodiment, the elongation rate factor can be at least
about a 2.5% decrease, such as at least about a 5% decrease, at
least about a 7.5% decrease, at least about a 10% decrease, at
least about a 12.5% decrease, at least about a 15% decrease, at
least about a 17.5% decrease, or at least about a 20.0% decrease in
elongation rate from a conventionally treated backing material or
an untreated backing material. In an embodiment, the elongation
rate factor can be not greater than about a 100% decrease, such as
not greater than about a 75% decrease, or not greater than about a
50% decrease in elongation rate of a conventionally treated backing
material or an untreated backing material. The elongation rate
factor of the amino resin treated backing material can be within a
range comprising any pair of the previous upper and lower limits.
In a particular embodiment, the elongation rate factor of the amino
resin treated backing material can be in a range of not less than
about a 2.5% decrease to not greater than about a 100% decrease of
a conventionally treated backing material or an untreated backing
material.
[0066] In an embodiment, the amino resin treated backing material
can have a certain percentage of visually detectable bubbles. In an
embodiment, the percentage of visually detectable bubbles can be
from 5% to 0% of the surface area of the amino resin treated making
material. In a particular embodiment, the amino resin treated
backing material is free of visually detectable bubbles.
[0067] In accordance with an embodiment, the amino resin treated
backing material can have a particular body retention factor. The
body retention factor can be defined as a ratio of the tensile
strain of the amino resin treated backing material to the tensile
strain of a conventionally treated backing material or an untreated
backing material (lower body retention factor is better).
Alternatively, the body retention factor can be defined as a
percent decrease compared to the tensile strain of a conventionally
treated backing material or an untreated backing material.
[0068] In accordance with an embodiment, the amino resin treated
backing material can have a particular body retention factor that
can be defined as a ratio of maximum tensile strain at 500 N or
100N of an amino resin treated backing material to a conventionally
treated backing material or an untreated backing material. In an
embodiment, the body retention factor can be not greater than 1.0,
such as not greater than 0.95, not greater than 0.9, not greater
than 0.85, not greater than 0.80, or not greater than 0.75. In an
embodiment, the body retention factor can be not less than about
0.6, such as not less than about 0.5, or not less than about 0.4.
The body retention factor of the amino resin treated backing
material can be within a range comprising any pair of the previous
upper and lower limits. In a particular embodiment, the body
retention factor of the amino resin treated backing material can be
in a range of not greater than about 1.0 to not less than about 0.4
of a conventionally treated backing material or an untreated
backing material.
[0069] In an embodiment, the body retention factor can be at least
about a 2.5% decrease, such as at least about a 5% decrease, at
least about a 7.5% decrease, at least about a 10% decrease, at
least about a 12.5% decrease, at least about a 15% decrease, at
least about a 17.5% decrease, or at least about a 20.0% decrease in
tensile strain from a conventionally treated backing material or an
untreated backing material. In an embodiment, the body retention
factor can be not greater than about a 100% decrease, such as not
greater than about a 75% decrease, not greater than about a 50%
decrease, or not greater than about a 40% decrease in tensile
strain of a conventionally treated backing material or an untreated
backing material. The body retention factor of the amino resin
treated backing material can be within a range comprising any pair
of the previous upper and lower limits. In a particular embodiment,
the body retention factor of the amino resin treated backing
material can be in a range of not less than about a 12.5% decrease
to not greater than about a 100% decrease of a conventionally
treated backing material or an untreated backing material.
Preparation of a Coated Abrasive
[0070] The amino resin treated backing material can be used to make
a coated abrasive article. In an embodiment, an abrasive layer is
disposed on the amino resin treated backing material. Optionally, a
size coat, a supersize coat, a back coat or any other number of
compliant or intermediary layers known in the art of making a
coated abrasive article can be applied to the amino resin treated
backing to construct a coated abrasive article.
Abrasive Layer
[0071] An abrasive layer can comprise a make coat or an abrasive
slurry. The make coat or abrasive slurry can comprise a plurality
of abrasive particles, also referred to herein as abrasive grains,
retained by a polymer binder composition. The polymer binder
composition can be an aqueous composition. The polymer binder
composition can be a thermosetting composition, a radiation cured
composition, or a combination thereof.
Abrasive Grains
[0072] Abrasive grains can include essentially single phase
inorganic materials, such as alumina, silicon carbide, silica,
ceria, and harder, high performance superabrasive grains such as
cubic boron nitride and diamond. Additionally, the abrasive grains
can include composite particulate materials. Such materials can
include aggregates, which can be formed through slurry processing
pathways that include removal of the liquid carrier through
volatilization or evaporation, leaving behind green aggregates,
optionally followed by high temperature treatment (i.e., firing) to
form usable, fired aggregates. Further, the abrasive regions can
include engineered abrasives including macrostructures and
particular three-dimensional structures.
[0073] In an exemplary embodiment, the abrasive grains are blended
with the binder formulation to form abrasive slurry. Alternatively,
the abrasive grains are applied over the binder formulation after
the binder formulation is coated on the backing. Optionally, a
functional powder may be applied over the abrasive regions to
prevent the abrasive regions from sticking to a patterning tooling.
Alternatively, patterns may be formed in the abrasive regions
absent the functional powder.
[0074] The abrasive grains may be formed of any one of or a
combination of abrasive grains, including silica, alumina (fused or
sintered), zirconia, zirconia/alumina oxides, silicon carbide,
garnet, diamond, cubic boron nitride, silicon nitride, ceria,
titanium dioxide, titanium diboride, boron carbide, tin oxide,
tungsten carbide, titanium carbide, iron oxide, chromia, flint,
emery. For example, the abrasive grains may be selected from a
group consisting of silica, alumina, zirconia, silicon carbide,
silicon nitride, boron nitride, garnet, diamond, co-fused alumina
zirconia, ceria, titanium diboride, boron carbide, flint, emery,
alumina nitride, and a blend thereof. Particular embodiments have
been created by use of dense abrasive grains comprised principally
of alpha-alumina.
[0075] The abrasive grain may also have a particular shape. An
example of such a shape includes a rod, a triangle, a pyramid, a
cone, a solid sphere, a hollow sphere, or the like. Alternatively,
the abrasive grain may be randomly shaped.
[0076] In an embodiment, the abrasive grains can have an average
grain size not greater than 800 microns, such as not greater than
about 700 microns, not greater than 500 microns, not greater than
200 microns, or not greater than 100 microns. In another
embodiment, the abrasive grain size is at least 0.1 microns, at
least 0.25 microns, or at least 0.5 microns. In another embodiment,
the abrasive grains size is from about 0.1 microns to about 200
microns and more typically from about 0.1 microns to about 150
microns or from about 1 micron to about 100 microns. The grain size
of the abrasive grains is typically specified to be the longest
dimension of the abrasive grain. Generally, there is a range
distribution of grain sizes. In some instances, the grain size
distribution is tightly controlled.
Binder--Make Coat
[0077] The binder of the make coat or the size coat may be formed
of a single polymer or a blend of polymers. For example, the binder
may be formed from epoxy, acrylic polymer, or a combination
thereof. In addition, the binder may include filler, such as
nano-sized filler or a combination of nano-sized filler and
micron-sized filler. In a particular embodiment, the binder is a
colloidal binder, wherein the formulation that is cured to form the
binder is a colloidal suspension including particulate filler.
Alternatively, or in addition, the binder may be a nanocomposite
binder including sub-micron particulate filler.
[0078] The binder generally includes a polymer matrix, which binds
abrasive grains to the backing or compliant coat, if present.
Typically, the binder is formed of cured binder formulation. In one
exemplary embodiment, the binder formulation includes a polymer
component and a dispersed phase.
[0079] The binder formulation may include one or more reaction
constituents or polymer constituents for the preparation of a
polymer. A polymer constituent may include a monomeric molecule, a
polymeric molecule, or a combination thereof. The binder
formulation may further comprise components selected from the group
consisting of solvents, plasticizers, chain transfer agents,
catalysts, stabilizers, dispersants, curing agents, reaction
mediators and agents for influencing the fluidity of the
dispersion.
[0080] The polymer constituents can form thermoplastics or
thermosets. By way of example, the polymer constituents may include
monomers and resins for the formation of polyurethane, polyurea,
polymerized epoxy, polyester, polyimide, polysiloxanes (silicones),
polymerized alkyd, styrene-butadiene rubber,
acrylonitrile-butadiene rubber, polybutadiene, or, in general,
reactive resins for the production of thermoset polymers. Another
example includes an acrylate or a methacrylate polymer constituent.
The precursor polymer constituents are typically curable organic
material (i.e., a polymer monomer or material capable of
polymerizing or crosslinking upon exposure to heat or other sources
of energy, such as electron beam, ultraviolet light, visible light,
etc., or with time upon the addition of a chemical catalyst,
moisture, or other agent which cause the polymer to cure or
polymerize). A precursor polymer constituent example includes a
reactive constituent for the formation of an amino polymer or an
aminoplast polymer, such as alkylated urea-formaldehyde polymer,
melamine-formaldehyde polymer, and alkylated
benzoguanamine-formaldehyde polymer; acrylate polymer including
acrylate and methacrylate polymer, alkyl acrylate, acrylated epoxy,
acrylated urethane, acrylated polyester, acrylated polyether, vinyl
ether, acrylated oil, or acrylated silicone; alkyd polymer such as
urethane alkyd polymer; polyester polymer; reactive urethane
polymer; phenolic polymer such as resole and novolac polymer;
phenolic/latex polymer; epoxy polymer such as bisphenol epoxy
polymer; isocyanate; isocyanurate; polysiloxane polymer including
alkylalkoxysilane polymer; or reactive vinyl polymer. The binder
formulation may include a monomer, an oligomer, a polymer, or a
combination thereof. In a particular embodiment, the binder
formulation includes monomers of at least two types of polymers
that when cured may crosslink. For example, the binder formulation
may include epoxy constituents and acrylic constituents that when
cured form an epoxy/acrylic polymer.
Size Coat
[0081] The coated abrasive article can comprise a size coat
overlying the abrasive layer. The size coat can be the same as or
different from the polymer binder composition used to form the
abrasive layer. The size coat can comprise any conventional
compositions known in the art that can be used as a size coat. In
an embodiment, the size coat comprises a conventionally known
composition overlying the polymer binder composition of the
abrasive layer. In another embodiment, the size coat comprises the
same ingredients as the polymer binder composition of the abrasive
layer. In a specific embodiment, the size coat comprises the same
ingredients as the polymer binder composition of the abrasive layer
and one or more hydrophobic additives. In a specific embodiment,
the hydrophobic additive can be a wax, a halogenated organic
compound, a halogen salt, a metal, or a metal alloy.
Supersize Coat
[0082] The coated abrasive article can comprise a supersize coat
overlying the size coat. The supersize coat can be the same as or
different from the polymer binder composition or the size coat
composition. The supersize coat can comprise any conventional
compositions known in the art that can be used as a supersize coat.
In an embodiment, the supersize coat comprises a conventionally
known composition overlying the size coat composition. In another
embodiment, the supersize coat comprises the same ingredients as at
least one of the size coat composition or the polymer binder
composition of the abrasive layer. In a specific embodiment, the
supersize coat comprises the same composition as the polymer binder
composition of the abrasive layer or the composition of the size
coat plus one or more grinding aids.
[0083] Suitable grinding aids can be inorganic based; such as
halide salts, for example sodium cryolite, and potassium
tetrafluoroborate; or organic based, such as sodium lauryl
sulphate, or chlorinated waxes, such as polyvinyl chloride. In an
embodiment, the grinding aid can be an environmentally sustainable
material.
[0084] Illustrated in FIG. 3 is an embodiment of a coated abrasive
article 300, commonly called a "coated abrasive." The coated
abrasive 300 includes a backing 301 and an abrasive layer 303
disposed on the backing 301. The abrasive layer 303 comprises a
plurality of abrasive particles 305 that are retained by a polymer
binder composition 307. The polymer binder composition 307 is
commonly called a "make coat" where the abrasive particles 305 are
disposed on the surface 309 of the polymer binder composition and
are partially embedded in the polymer binder composition. The
coated abrasive 300 can also include a size coat 311 overlying the
abrasive layer 303. Optionally, a supersize coat (not illustrated)
can be overlying the size coat 311. Further, an adhesion promoting
layer (not illustrated) can optionally be located between the
backing 301 and the abrasive layer 303.
[0085] Illustrated in FIG. 4 is another embodiment of a coated
abrasive article 400. The coated abrasive 400 includes a backing
401 and an abrasive layer 403 disposed on the backing 401. The
abrasive layer 403 comprises a plurality of abrasive particles 405
dispersed within a polymer binder composition 407. The abrasive
layer 403 is commonly called an "abrasive slurry coat" where the
abrasive particles 405 are dispersed within the polymer binder
composition 407. The coated abrasive 400 can also include a size
coat 409 overlying the abrasive layer 403. Optionally, a supersize
coat (not illustrated) can be overlying the size coat 409. Further,
an adhesion promoting layer (not illustrated) can optionally be
located between the backing 401 and the abrasive layer 403.
EXAMPLES
Example 1
Forming an Amino Resin Treated Fabric Backing
[0086] An amino resin solution was prepared by mixing together the
following ingredients: [0087] 80.0 parts by weight alkylated
trimethylol melamine ("ATMM") amino resin [0088] 18.9 parts by
weight water [0089] 1.1 parts by weight catalyst
[0090] The water was added to the amino resin and mixed to achieve
a desired viscosity. The catalyst was then added to the mixture to
form the amino resin solution. The solution was maintained in a
temperature range of about 20-45.degree. C.
[0091] A polyester blend fabric, about 90% polyester and about 10%
cotton, was then impregnated with the amino resin solution by
submerging the fabric in the amino resin solution. The saturated
fabric was subsequently passed through a pair of squeeze-off rolls
at about 25.degree. C. to squeeze out excess amino resin solution.
The saturated fabric was passed through a heating tunnel to
partially cure the amino resin. The heating tunnel had several
heating zones having a temperature in a range of 125.degree. C. to
150.degree. C. and the residence time in the heating tunnel lasted
from 0.5 minutes to 5 minutes. The amino resin (the "addon") was
partially cured (i.e., not completely cured) and the amino resin
impregnated fabric was not tacky to touch (i.e., the amino resin
impregnated fabric did not stick to fingers). The partially cured
amino resin treated fabric was then wound onto a roll and stored
for subsequent processing to make coated abrasive articles.
Example 2
Catalyst Effect
[0092] An amino resin solution was prepared by mixing 80 parts by
weight of alkylated trimethylol melamine (ATMM) amino resin with
different amounts of catalyst and water as listed in Table 1. A
polyester blend fabric, 90 wt % polyester and 10 wt % cotton, was
saturated by submerging the fabric in the amino resin solution and
then pressed to squeeze out excess solution. The weight of the
add-on ATMM amino resin was 100 grams per square meter (gsm) of the
fabric. The saturated fabric was then heated in an oven at
150.degree. C. for 1 min. The texture of the impregnated fabric was
examined by visual inspection and hand touch. The observations are
listed in Table 2.
TABLE-US-00001 TABLE 1 Amino Resin Sample Solutions Chemical Sample
1 Sample 2 Sample 3 Sample 4 Sample 5 Amino resin 80.0 wt % 80.0 wt
% 80 wt % 80 wt % 80 wt % Catalyst 2.4 wt % 1.6 wt % 1.1 wt % 0.8
wt % 0.0 wt % 4040 Water 17.6 wt % 18.4 wt % 18.9 wt % 19.2 wt % 20
wt %
TABLE-US-00002 TABLE 2 Observations of Amino Resin Treated Fabric
Treated fabric Sample 1 Sample 2 Sample 3 Sample 4 Sample 5
observation Fabric is dry, Fabric is Fabric is Fabric is tacky
Fabric is very with bubbles smooth, not smooth, not tacky tacky
tacky
[0093] For Sample 1, the treated fabric had a dry surface with
visible bubbles in the cured resin. Samples 2 and 3 produced good
results, where the treated fabric was smooth to the touch, not
tacky, and did not have any visible bubbles. For Sample 4 the
treated fabric was tacky to the touch and did not have any visible
bubbles. For Sample 5 the treated fabric was very tacky to the
touch and did not have any visible bubbles.
Example 3
Rheology Testing and Reaction Temperature
[0094] Two amino resins solutions were prepared. The first amino
resin solution included catalyst ("with catalyst") and was
comprised of: [0095] 80.0 parts by weight alkylated trimethylol
melamine ("ATMM") amino resin; [0096] 18.6 parts by weight water;
and [0097] 1.4 parts by weight catalyst.
[0098] The second amino resin solution did not include catalyst
("without catalyst") and was comprised of: [0099] 80.0 parts by
weight alkylated trimethylol melamine ("ATMM") amino resin and
[0100] 20 parts by weight water.
[0101] Rheology testing was conducted on two samples each of the
amino resin solution with catalyst ("with catalyst") and without
catalyst ("without catalyst") by measuring the storage modulus (G')
as a function of temperature. The results are shown in FIG. 5. The
data shows that as the temperature increases and the amino resin
starts and continues to crosslink, the storage modulus increases.
No significant difference was observed in the starting temperature
of the crosslinking reaction between the amino resin solution with
catalyst and the amino resin solution without catalyst. However,
for the solution without catalyst, the storage modulus reached 1
MPa at approximately 150.degree. C. In contrast, for the solution
with catalyst, the storage modulus reached 1 MPa at approximately
100.degree. C. This indicates that the rate of the crosslinking
reaction of the amino resin solution with catalyst is much higher
than the amino resin solution without the catalyst. Importantly and
beneficially, the catalyst significantly reduced the reaction
temperature required to achieve desired crosslinking, thus
providing a significant reduction in the amount of time and energy
required to cure the amino resin and produce the treated backing
material.
Example 4
Tensile Strength and Elongation Testing
[0102] Tensile strength and elongation rate testing of a
comparative treated fabric sample and an inventive treated fabric
sample was conducted.
[0103] An inventive amino resins solution was prepared by mixing:
[0104] 80.0 parts by weight alkylated trimethylol melamine ("ATMM")
amino resin [0105] 18.9 parts by weight water [0106] 1.1 parts by
weight catalyst
[0107] A comparative phenolic resin solution was prepared by
mixing: [0108] 80.0 parts by weight phenolic resin [0109] 20.0
parts by weight water
[0110] A piece (gage length 20 cm, width 5 cm) of polyester blend
fabric (90 wt % polyester and 10 wt % cotton) was submerged in the
inventive amino resin solution and pressed to squeeze out excess
solution. The weight of the addon amino resin was in a range of 45
to 50 grams per square meter (gsm) of fabric. The saturated fabric
was then heated in an oven at about 105.degree. C. for 17 hours to
completely cure the amino resin and produce an amino resin treated
fabric.
[0111] A comparative phenolic resin treated fabric was produced in
the same manner by submerging a piece of polyester blend fabric in
the comparative phenolic resin solution, squeezing out excess
solution, and curing in an oven at the same time and temperature to
produce a comparative phenolic resin treated fabric.
[0112] The inventive amino resin treated fabric and the comparative
phenolic resin treated fabric were then soaked in water at room
temperature for different periods of time. The tensile strength and
elongation rate of the different treated fabrics was measured and
is presented in Table 3 and Table 4, below.
TABLE-US-00003 TABLE 3 Tensile Strength Tensile strength (N, in
warp direction) Soaking time in water 0 hr 0.5 hr 1 hr 2.5 hr 2 hr
3 hr Phenolic Resin 1986.31 1911.07 1965.48 1942.75 1956.37 1968.72
Sample Amino Resin 2268.99 2374.7 2436.02 2371.05 2427.65 2395.56
Sample % difference 14.2% 24.3% 23.9% 22.0% 24.1% 21.7% increase
increase increase increase increase increase
TABLE-US-00004 TABLE 4 Elongation rate Elongation rate (%, in warp
direction) at 600 N Soaking time in water 0 hr 0.5 hr 1 hr 2.5 hr 2
hr 3 hr Phenolic Resin Sample 1.29 1.82 1.88 1.78 1.77 1.85 Amino
Resin Sample 0.98 1.14 1.16 1.16 1.2 1.18 % difference 24.0% 37.4%
38.3% 34.8% 32.2% 36.2% decrease decrease decrease decrease
decrease decrease
[0113] The data shows that the amino resin treated polyester fabric
has higher tensile strength than phenolic resin treated polyester
fabric (at 600 N force). Amino resin treated polyester fabric has
lower elongation rate (at 600 N force) than phenolic resin treated
polyester fabric.
Example 5
Body Retention Testing
[0114] Inventive amino resin treated fabric and comparative
phenolic resin treated fabric was prepared as described in Example
5 above. Three specimens of the amino resin treated fabric and
three specimens of phenolic resin treated fabric were subjected to
body retention testing.
[0115] The body retention testing was conducted by clamping two
opposite sides of a fabric specimen with two clamps so that the
fabric specimen was strained in the warp direction. Testing speed
was 50 mm/min.
[0116] Body retention is expressed as an average tensile strain
after 10 cycles of elongation of the fabric with maximum loading
force at 600 N. The results of the body retention test data for the
amino resin treated fabric specimens and the phenolic resin treated
fabric specimens are presented in FIG. 6 and FIG. 7, respectively,
and in Table 5, below.
[0117] A lower average tensile strain after 10 cycles of elongation
force loading was observed for the amino resin treated fabric
specimens as compared with the phenolic resin treated fabric
specimens. Additionally, the amino resin treated fabric specimens
had better body retention (i.e., recovered there original shape)
after 10 cycles of stretching compared to the phenolic resin
treated fabric specimens.
TABLE-US-00005 TABLE 5 Tensile strain (%) Max. Min. strain 1 Strain
1 Min. strain 10 cycle cycle Max. strain 10 cycles (500 N) (100 N)
cycles (500 N) (load 1 N) Amino Resin 1.1 0.29 1.32 0.16 Samples
Phenolic Resin 1.36 0.42 1.55 0.24 Samples % difference 19.1% 30.9%
14.8% decrease 33.3% decrease decrease decrease ratio 0.81 0.69
0.85 0.67
Example 6
Edge Waviness Test
[0118] A comparative phenolic resin treated polyester fabric sample
and an inventive amino resin treated polyester fabric sample were
prepared as described above in Examples 4 and 5.
[0119] The edge waviness of the samples was examined. The edge of
the inventive amino resin treated fabric is shown in FIG. 8. The
edge of the comparative phenolic resin treated fabric is shown in
FIG. 9. The maximum edge waviness (i.e., the maximum deviation
inward or outward from a straight edge) of the treated fabric
specimens was measured.
[0120] The amino resin treated fabric had no visible edge waviness.
In contrast, the phenolic resin treated fabric had an edge waviness
of 10 mm. The reduced edge waviness of the amino resin treated
fabric is beneficial because it provides a flatter and more uniform
surface for the application of an abrasive layer, which in turn
reduces waste and processing costs associated with making a coated
abrasive article with the amino resin treated fabric, and is also
expected to maintain or enhance the abrasive performance.
Example 7
Tensile Strength and Elongation Rate Testing
[0121] An amino resin treated fabric is prepared similarly as
described in Example 4, except that 72 parts by weight of ATMM
amino resin was mixed with 1 part by weight of catalyst and 26
parts by weight of water to make the amino resin solution.
Polyester blend (90 wt % polyester, 10 wt % cotton) fabric (gage
length 20 cm, width 5 cm) was submerged in the amino resin solution
and pressed to squeeze out excess solution. The weight of the addon
resin was 110 to 115 grams per square meter (gsm) of the fabric.
The saturated fabric was then heated in an oven at about
105.degree. C. for 17 hours to completely cure the amino resin. The
tensile strength and elongation rate at 600 N was tested at 200
mm/min. Comparative results of the amino treated polyester fabric
versus an untreated polyester fabric are listed in table 6,
below.
TABLE-US-00006 TABLE 6 Tensile strength and elongation rate of
treated and untreated fabric Treated Untreated warp weft warp weft
Tensile strength (N) 2935.4 1849 2232.5 1693 Elongation rate (%)
4.9 4.4 10 7.7
[0122] The data shows that the amino resin treated fabric had a
significantly greater tensile strength in both the warp direction
((2935.4-2232.5/2232.5)*100=31.5% increase) and weft direction
((1849-1693/1693)*100=9.2% increase). Additionally, the elongation
rate of the amino resin treated fabric was significantly lower than
the untreated fabric in both the warp direction
((4.9-10/10)*100=51% decrease) and the weft direction
((4.4-7.7/7.7)*100=42.8% decrease).
[0123] In the foregoing, reference to specific embodiments and the
connections of certain components is illustrative. It will be
appreciated that reference to components as being coupled or
connected is intended to disclose either direct connection between
said components or indirect connection through one or more
intervening components as will be appreciated to carry out the
methods as discussed herein. As such, the above-disclosed subject
matter is to be considered illustrative, and not restrictive, and
the appended claims are intended to cover all such modifications,
enhancements, and other embodiments, which fall within the true
scope of the present invention. Moreover, not all of the activities
described above in the general description or the examples are
required, that a portion of a specific activity can not be
required, and that one or more further activities can be performed
in addition to those described. Still further, the order in which
activities are listed is not necessarily the order in which they
are performed.
[0124] The disclosure is submitted with the understanding that it
will not be used to limit the scope or meaning of the claims. In
addition, in the foregoing disclosure, certain features that are,
for clarity, described herein in the context of separate
embodiments, can also be provided in combination in a single
embodiment. Conversely, various features that are, for brevity,
described in the context of a single embodiment, can also be
provided separately or in any subcombination. Still, inventive
subject matter can be directed to less than all features of any of
the disclosed embodiments.
[0125] Benefits, other advantages, and solutions to problems have
been described above with regard to specific embodiments. However,
the benefits, advantages, solutions to problems, and any feature(s)
that can cause any benefit, advantage, or solution to occur or
become more pronounced are not to be construed as a critical,
required, or essential feature of any or all the claims.
[0126] Thus, to the maximum extent allowed by law, the scope of the
present invention is to be determined by the broadest permissible
interpretation of the following claims and their equivalents, and
shall not be restricted or limited by the foregoing detailed
description.
[0127] Item. 1. An amino resin treated backing material
comprising:
an amino resin comprising a modified melamine formaldehyde resin
having a formula
##STR00006##
wherein R1, R2, R3 each represents an independent substituent
selected from hydrogen and alkyl groups having one to four carbon
atoms; and a backing material, wherein said backing material is
impregnated with said amino resin.
[0128] Item 2. An amino resin treated backing material
comprising:
an amino resin comprising an alkylated trimethylol melamine
obtained by reaction of trimethylol melamine with alkanol; and a
backing material, wherein said backing material is impregnated with
said amino resin.
[0129] Item 3. The amino resin treated backing material according
to item 2, wherein the alkanol has 1 to 4 carbon atoms.
[0130] Item 4. The amino resin treated backing material according
to item 3, wherein the alkanol is methanol.
[0131] Item 5. The amino resin treated backing material according
to item 1 or 2, wherein the backing material comprises a polyester
fabric.
[0132] Item 6. The amino resin treated backing material according
to item 5, wherein the backing material further comprises cotton,
viscose, polyamine, or combinations thereof.
[0133] Item 7. The amino resin treated backing material according
to item 5, wherein the polyester fabric comprises at least about 50
wt % polyester.
[0134] Item 8. The amino resin treated backing material according
to item 1 or 2, wherein the amount of impregnation is equal to an
add-on weight of amino resin solution in a range from 10 g/m.sup.2
to 300 g/m.sup.2 of backing material.
[0135] Item 9. The amino resin treated backing material according
to item 8, wherein the add-on amino resin solution is cured at a
temperature of at least 95.degree. C.
[0136] Item 10. The amino resin treated backing material according
to item 9, wherein the add-on amino resin solution is cured at a
temperature of not greater than 175.degree. C.
[0137] Item 11. The amino resin treated backing material according
to item 9, wherein the add-on amino resin solution is at least
partially cured.
[0138] Item 12. The amino resin treated backing material according
to item 11, wherein the backing material is tack free.
[0139] Item 13. The amino resin treated backing material according
to item 12, wherein the tack free cure time is within a range of 30
to 300 seconds.
[0140] Item 14. The amino resin treated backing material according
to item 11, wherein the tensile strength factor is within a range
of 1.0 to 2.5.
[0141] Item 15. The amino resin treated backing material according
to item 11, having an elongation rate factor within a range of not
less than 0.3 to not greater than 1.0.
[0142] Item 16. The amino resin treated backing material according
to item 12, wherein the amino resin treated backing material is
free of bubbles.
[0143] Item 17. The amino resin treated backing material according
to item 11, having a body retention factor within a range of in a
range of not less than about 0.4 to not greater than about 1.0.
[0144] Item 18. The amino resin treated backing material according
to item 11, wherein the amino resin treated backing material has an
edge waviness of 3 mm or less.
[0145] Item 19. A coated abrasive article comprising:
an amino resin treated backing material according to item 1 or 2,
and an abrasive layer disposed on the amino resin treated backing
material.
[0146] Item 20. A coated abrasive article comprising:
an amino resin treated backing material impregnated with a cured
modified melamine formaldehyde resin having the formula:
##STR00007##
wherein R1, R2, R3 each represents an independent substituent
selected from hydrogen and alkyl groups having one to four carbon
atoms; and an abrasive layer disposed on the amino resin treated
backing material.
[0147] Item 21. A process of making an amino resin treated backing
material comprising:
mixing water, catalyst, and a modified melamine formaldehyde resin
to form an amino resin solution, saturating a backing material with
said amino resin solution to form a saturated backing material; and
curing said saturated backing material to form the amino resin
treated backing material, wherein the modified melamine
formaldehyde resin has the formula
##STR00008##
wherein R1, R2, R3 each represents an independent substituent
selected from a hydrogen or an alkyl group having one to four
carbon atoms.
[0148] Item 22. The process according to item 21, further
comprising adjusting the amount of saturation of the backing
material prior to curing the saturated backing material.
[0149] Item 23. The process according to item 21, wherein the
saturated backing material is cured at a temperature in a range of
100.degree. C. to 150.degree. C.
[0150] Item 24. The process according to item 23, wherein the
catalyst is selected from the group consisting of phosphoric acid,
alkyl acid phosphates, amine blocked alkyl benzene sulfonic acid,
hydrochloric acid, naphthalene sulfonic acid, alkyl phenyl
phosphate, alkyl benzene sulfonic acid, blocked para toluene
sulfonic acid(p-TSA), combinations thereof.
[0151] Item 25. The process according to item 21, wherein the
weight ratio of catalyst to amino resin is within a range from
1:800 to 1:16.
* * * * *