Abrasive article reinforced by discontinuous fibers

• US 9,776,303 B2
• Filed: 06/27/2014
• Issued: 10/03/2017
• Est. Priority Date: 06/28/2013
• 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: Klett, Michael W., Csillag, Frank J., Parsons, Steven F.
• Primary Examiner(s): Olsen, Kaj K
• Assistant Examiner(s): Moore, Alexandra M
• Application Number:
  US14/317,117
• Publication Number:
  US 20150000204A1
• Time in Patent Office: 1,194 Days
• CPC Class Codes: B24D 3/20 and being essentially organic
• CPC Class Codes: B24D 3/344 the bonding agent being organic
• CPC Class Codes: B24D 5/04 with reinforcing means
• CPC Class Codes: B24D 7/04 with reinforcing means
• CPC Class Codes: C03C 25/50 Coatings containing organic materials only

Abstract

An abrasive article has an abrasive portion and chopped strand fibers (CSF) with enhanced strength and/or fracture of toughness. The CSF may be coated with a thermoplastic having a loss on ignition of at least about 2 wt %. The CSF can have a primary coating and a secondary coating on the primary coating. At least some of the CSF can have a length of at least about 6.3 mm.

Claims

1. An abrasive article, comprising:

an abrasive portion having an organic bond and abrasive particles; and

a reinforcement comprising chopped strand fibers (CSF) coated with a primary coating and a secondary coating on the primary coating, wherein the primary coating comprises a direct sized thermoset coating having a loss on ignition (LOI) of less than about 2 wt % and the secondary coating comprises a thermoplastic coating having a loss on ignition (LOI) of at least about 2.4 wt %, and wherein at least a portion of the chopped strand fibers (CSF) are in direct contact with each other.

2. The abrasive article of claim 1, wherein the thermoset coating comprises a phenolic resin.

3. The abrasive article of claim 1, wherein the thermoplastic coating comprises polyurethane.

4. The abrasive article of claim 1, wherein the CSF comprises a yield in a range of about 134 TEX (3700 yd/lb) to about 1830 TEX (271 yd/lb).

5. The abrasive article of claim 1, wherein the thermoplastic coating comprises at least one of thermoplastic novolac, phenoxy and polyurethane.

6. The abrasive article of claim 1, wherein less than about 10% of the thermoplastic coating is cross-linked.

7. The abrasive article of claim 1, wherein the CSF are at least one of:

(a) dispersed in at least a portion of the abrasive article; and

(b) formed as at least one discrete layer in the abrasive mix.

8. The abrasive article of claim 1, wherein the abrasive article is a wheel having an axis, an outer diameter (OD) and an inner diameter (ID), and a maximum length of the CSF is not greater than (OD−

ID)/2.

9. The abrasive article of claim 1, wherein the abrasive article comprises a volume percentage of the CSF of at least about 1 vol %, and not greater than about 25 vol %.

10. The abrasive article of claim 1, wherein the abrasive article comprises about 25 vol % to about 50 vol % of the organic bond, about 40 vol % to about 70 vol % of the abrasive particles, and about 6 vol % to about 12 vol % of the CSF.

11. The abrasive article of claim 1, wherein the secondary coating is not cross-linked.

12. The abrasive article of claim 1, wherein at least some of the chopped strand fibers (CSF) have a length of at least about 6.3 mm.

13. The abrasive article of claim 12, wherein the abrasive article comprises a volume percentage of the CSF of at least about 1 vol %, and not greater than about 25 vol %.