Abrasive article

• US 9,855,639 B2
• Filed: 06/27/2014
• Issued: 01/02/2018
• 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., Cichowlas, Tyler B., Dhami, Davinder S., Lavallee, Jr., Lawrence J.
• Primary Examiner(s): Smith, Jennifer A
• Assistant Examiner(s): MOORE, ALEXANDRA MARIE
• Application Number:
  US14/317,340
• Publication Number:
  US 20150000206A1
• Time in Patent Office: 1,285 Days
• CPC Class Codes: B24D 11/02 Backings, e.g. foils, webs, mesh fabrics
• CPC Class Codes: B24D 18/0009 using moulds or presses
• CPC Class Codes: B24D 3/22 Rubbers synthetic or natural
• 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: B24D 5/04 with reinforcing means
• CPC Class Codes: B24D 5/14 Zonally-graded wheels; Composite wheels comprising different abrasives
• CPC Class Codes: B24D 5/16 Bushings; Mountings
• CPC Class Codes: B24D 7/04 with reinforcing means
• CPC Class Codes: B24D 7/14 Zonally-graded wheels; Composite wheels comprising different abrasives
• CPC Class Codes: B24D 7/16 Bushings; Mountings

Abstract

An abrasive article has an abrasive portion with an organic bond and abrasive particles. The abrasive article has a non-abrasive portion (NAP) mounted to the abrasive portion. The NAP includes molding compound (MC) having chopped strand fibers (CSF). The CSF can be coated with a thermoplastic coating having a loss on ignition (LOI) of at least about 2.4 wt %, and the NAP having no abrasive particles. The NAP can include an MC having no abrasive particles with a MOHS scale hardness of at least about 9. The NAP may include CSF coated with a primary coating and a secondary coating on the primary coating. The NAP may have an outer diameter that is at least half of but not greater than an outer diameter of the abrasive article.

Claims

1. An abrasive article, comprising:

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

a non-abrasive portion (NAP) coupled to the abrasive portion, the NAP comprising a resin matrix comprising molding compound (MC) and a plurality of discrete chopped strand fiber bundles dispersed throughout the resin matrix, and wherein the NAP is free of abrasive particles.

2. The abrasive article of claim 1, wherein the NAP extends from a peripheral center of the abrasive article and has a diameter of not less than 30% of a diameter of the abrasive portion.

3. The abrasive article of claim 1, wherein the chopped strand fiber bundles comprise fiberglass.

4. The abrasive article of claim 1, wherein the NAP comprises a core and a back layer.

5. The abrasive article of claim 4, wherein the core and the back layer comprise the MC.

6. The abrasive article of claim 4, wherein an outer diameter of the back layer is greater than an outer diameter of the core.

7. The abrasive article of claim 4, wherein a combined axial thickness of the core and the back layer is greater than an axial thickness of the abrasive portion.

8. The abrasive article of claim 4, wherein the back layer is contiguous with the core.

9. The abrasive article of claim 4, wherein a combined axial thickness of the back layer and the core is substantially equal to an axial thickness of the abrasive article.

10. The abrasive article of claim 1, wherein the NAP comprises at least one reinforcement different than the chopped strand fiber bundles selected from the group consisting of a continuous fiber mat, needled fiber mat, continuous glass web, chopped carbon fibers, chopped aramid fibers, chopped polymer fibers, milled fibers, and microfibers.

11. The abrasive article of claim 1, wherein the MC comprises at least one curing additive comprising hexamethylene tetramine (HMTA), polybenzoxazole (PBO), paraformaldehyde, melamine-formaldehyde resin, phenols or resorcinol with methylol functionality, multifunctional epoxy, cyanate esters, multifunctional isocyanate or any combination thereof.

12. The abrasive article of claim 1, wherein the MC comprises at least one rubber material, elastomeric material, thermoplastic material or any combination thereof.

13. The abrasive article of claim 1, wherein the NAP comprises at least about 20 vol % chopped strand fiber bundles and not greater than about 40 vol % chopped strand fiber bundles.

14. The abrasive article of claim 1, wherein the chopped strand fiber bundles are coated with a thermoplastic coating having a loss on ignition (LOI) of at least about 2.4 wt %.

15. The abrasive article of claim 1, further comprising a back layer mounted to the abrasive portion, and the back layer comprises discrete elastomeric particles and chopped strand fibers bundles, and at least some of the chopped strand fiber bundles have a length of at least about 6.3 mm.

16. The abrasive article of claim 1, wherein the chopped strand fiber bundles have a primary coating and a secondary coating, and wherein the secondary coating comprises a thermoplastic novolac, phenoxy, polyurethane, or any combination thereof.

17. The abrasive article of claim 1, wherein the MC extends as a matrix throughout a total volume of the NAP, and wherein the chopped strand fiber bundles are dispersed completely throughout the matrix of the MC.

18. The abrasive article of claim 1, wherein the NAP has an axial thickness of not less than about 30% of an overall axial thickness of the abrasive article.

19. The abrasive article of claim 1, wherein the MC is at least one of a bulk molding compound (BMC) and a sheet molding compound (SMC).

20. The abrasive article of claim 1, wherein the abrasive article does not comprise a continuous glass web reinforcement.