Abrasive articles having abrasive layer bond system derived from solid, dry-coated binder precursor particles having a fusible, radiation curable component

• US 20020123548A1
• Filed: 12/20/2001
• Published: 09/05/2002
• Est. Priority Date: 05/01/1998
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Larson, Eric G., Dahlke, Gregg D., Thurber, Ernest L., Stubbs, Roy
• Granted Patent: US 6,753,359 B2
• Time in Patent Office: Days
• US Class Current: 524/394
• CPC Class Codes: B24D 11/001 Manufacture of flexible abrasive materials
• CPC Class Codes: B24D 11/005 Making abrasive webs
• CPC Class Codes: B24D 3/28 Resins or natural or synthetic macromolecular compounds B24D3/22 takes precedence
• CPC Class Codes: B24D 3/344 the bonding agent being organic
• CPC Class Codes: Y10T 428/24372 Particulate matter
• CPC Class Codes: Y10T 428/24413 Metal or metal compound

Abstract

The present invention involves the use of powder coating methods to form coated abrasives. In one embodiment, the powder is in the form of a multiplicity of binder precursor particles comprising a radiation curable component. In other embodiments, the powder comprises at least one metal salt of a fatty acid and optionally an organic component that may be a thermoplastic macromolecule, a radiation curable component, and/or a thermally curable macromolecule. In either embodiment, the powder exists as a solid under the desired dry coating conditions, but is easily melted at relatively low temperatures and then solidified also at reasonably low processing temperatures. The principles of the present invention can be applied to form make coats, size coats, and/or supersize coats, as desired.

Claims

1. A fusible powder, comprising 100 parts by weight of a metal salt of a fatty acid and 0 to 35 parts by weight of a fusible organic component.

2. The fusible powder of claim 1, wherein the fusible organic component is selected from the group consisting of a thermoplastic macromolecule, a thermally curable macromolecule, a radiation curable binder precursor, and combinations thereof.

3. The fusible powder of claim 1, wherein the metal salt of a fatty acid comprises calcium stearate and zinc stearate, wherein the weight ratio of the calcium stearate to the zinc stearate is in the range from 1:

1 to 9;

1.

4. The fusible powder of claim 1, further comprising up to 30 parts by weight of a fatty acid.

5. The fusible powder of claim 4, wherein the fatty acid is stearic acid.

6. The fusible powder of claim 4, wherein the powder comprises about 90 parts by weight of calcium stearate per about 10 parts of stearic acid.

7. A fusible powder comprising from about 5 to 100 parts by weight of a grinding aid and from 0 to about 95 parts by weight of a fusible organic component.

8. The fusible powder of claim 7 wherein the grinding aid is an organic halide, a halide salt, a metal, a metal alloy, or combinations thereof.