COATED ABRASIVE BACKINGS WITH CLOTH TREATED WITH COLLOIDAL SILICON OXIDE

• US 20110162286A1
• Filed: 12/23/2010
• Published: 07/07/2011
• Est. Priority Date: 12/29/2009
• Status: Active Grant

• Current Assignee: Saint-Gobain Abrasives Incorporated (Compagnie De Saint-Gobain), Saint-Gobain Abrasifs (Compagnie de Saint-Gobain SA)
• Original Assignee: Saint-Gobain Abrasives Incorporated (Compagnie De Saint-Gobain), Saint-Gobain Abrasifs (Compagnie de Saint-Gobain SA)
• Inventors: Yang, Yu Xiang, Feng, Lin Hua, Seshu, Adiseshaiah K.
• Granted Patent: US 8,940,063 B2
• Time in Patent Office: Days
• US Class Current: 51/298
• CPC Class Codes: B24D 11/001 Manufacture of flexible abrasive materials
• CPC Class Codes: B24D 11/02 Backings, e.g. foils, webs, mesh fabrics
• CPC Class Codes: B24D 3/004 with special coatings
• CPC Class Codes: Y10T 442/2738 Coating or impregnation intended to function as an adhesive to solid surfaces subsequently associated therewith

Abstract

A cloth backing for an abrasive article is treated by combining a phenolic resin, a latex and a colloidal silicon oxide composition to prepare a colloidal formulation, which is then applied to the cloth backing and cured. Coated abrasive articles are formed by applying a make coat formulation to the treated cloth backing, applying an abrasive and then curing the make coat formulation.

Claims

1. A method for treating a cloth backing of an abrasive article, comprising the steps of:

a) combining a phenolic resin, a latex and a colloidal silicon oxide composition, thereby preparing a colloidal formulation;

b) applying the colloidal formulation to a cloth backing; and

c) curing the colloidal formulation, thereby treating the cloth backing

2. The method of claim 1, wherein the colloidal silicon oxide has a colloid particle size in a range of between about 2 nanometers and about 200 nanometers.

3. The method of claim 2, wherein the phenolic resin is at least one member of the group consisting of a resole, a resole modified with a glycol, a diphenolic resin and a polyphenolic resin.

4. The method of claim 3, wherein the latex is at least one member of the group consisting of acrylic latex, butadiene-acrylonitrile latex and styrene-butadiene latex.

5. The method of claim 4, wherein the phenolic resin is present in the formulation in an amount in a range of between about 10% and 50% by weight of the formulation.

6. The method of claim 5, wherein the colloidal silicon oxide is present in the formulation in an amount in a range of between about 1% and about 10% by weight of the formulation.

7. The method of claim 6, wherein the latex is present in the formulation in an amount in a range of between about 30% and about 90% by weight of the formulation.

8. The method of claim 7, wherein the cloth backing includes at least one material selected from the group consisting of polycotton, cotton, polyester and nylon.

9. The method of claim 8, wherein the cloth backing includes polycotton.

10. The method of claim 9, wherein the formulation is applied to the cloth backing in amount in a range of between about 10 grams per square meter and about 120 grams per square meter.

11. The method of claim 10, wherein the formulation is applied to the cloth backing in an amount of about 25 grams per square meter.

12. A method of forming a coated abrasive article comprising the steps of:

a) combining a phenolic resin, a latex and a colloidal silicon oxide composition, thereby preparing a colloidal formulation;

b) applying the colloidal formulation, to a cloth backing;

c) curing the colloidal formulation, thereby treating the cloth backing;

d) coating the treated cloth backing with a make coat formulation;

e) applying an abrasive to the make coat formulation on the coated cloth backing; and

f) curing the make coat formulation, thereby forming the coated abrasive article.

13. The method of claim 12, wherein the colloidal silicon oxide has a colloid particle size in a range of between about 2 nanometers and about 200 nanometers.

14. The method of claim 13, wherein the phenolic resin is at least one member of the group consisting of a resole, a resole modified with a pheynol, a diphenolic resin and a polyphenolic resin.

15. The method of claim 14, wherein the latex is at least one member of the group consisting of acrylic latex, butadiene-acrylonitrile latex and styrene-butadiene latex.

16. The method of claim 15, wherein the phenolic resin is present in the formulation in an amount in a range of between about 10% and 50% by weight of the formulation.

17. The method of claim 16, wherein the colloidal silicon oxide is present in the formulation in an amount in a range of between about 1% and about 10% by weight of the formulation.

18. The method of claim 17, wherein the latex is present in the formulation in an amount in a range of between about 30% and about 90% by weight of the formulation.

19. The method of claim 18, wherein the cloth backing includes at least one material selected from the group consisting of polycotton, cotton, polyester and nylon.

20. The method of claim 19, wherein the cloth baking includes polycotton.

21. The method of claim 20, wherein the formulation is applied to the cloth backing in amount in a range of between about 10 grams per square meter and about 120 grams per square meter.

22. The method of claim 21, wherein the formulation is applied to the cloth backing in an amount of about 25 grams per square meter.

23. The method of claim 12, wherein the make the formulation includes at least one member selected from the group consisting of phenolic resin, latex and colloidal silicon oxide.

24. The method of claim 23, wherein the thickness of the coating of the make formulation on the cloth backing is in a range of between about 0.1 millimeter and about 1 millimeter.

25. The method of claim 24, wherein the abrasive includes at lease one member of the group consisting of Al₂O₃, ZrO₂ and SiC.

26. The method of claim 25, wherein the abrasive includes Al₂O₃.

27. The method of claim 26, wherein the amount of abrasive applied to the coated cloth backing is in a range of between about 30 grams per square meter and about 1000 grams per square meter.

28. The method of claim 12, wherein the colloidal formulation is cured for a period of time in a range of between about 1 minute and about 10 minutes, and at a temperature in a range of between about 90°

C. and about 160°

C.

29. The method of claim 12, wherein the make coat formulation is cured by heating the formulation for a period of time in a range of between about 15 minutes and about 60 minutes, and at a temperature in a range of between about 60°

C. and about 115°

C.

30. A treated cloth backing formed by a method, comprising the steps of:

a) combining a phenolic resin, a latex and colloidal silicon oxide composition, thereby preparing a colloidal formulation;

b) applying the colloidal formulation to a cloth backing; and

c) curing the colloidal formulation, thereby forming the treated the cloth backing.

31. An abrasive article formed by a method, comprising the steps of:

a) combining a phenolic resin, a latex and a colloidal silicon oxide composition, thereby preparing a colloidal formulation;

b) applying the colloidal formulation to a cloth backing;

c) curing the colloidal formulation;

thereby treating the cloth backing;

d) coating the treated cloth backing with a make formulation;

e) applying an abrasive to the coated cloth backing; and

f) curing the make formulation thereby forming the coated abrasive article.