Abrasive articles and methods of making same
First Claim
1. An abrasive article comprising(a) a plurality of abrasive particles and(b) a bond system which adheres the plurality of abrasive particles together, the bond system comprising a binder;
- the binder being formed from a binder precursor essentially free of organic solvent, the binder precursor comprising a blend of an urea-aldehyde resin and a water dilutable resole phenolic resin, the blend being catalyzed by an acid catalyst.
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Accused Products
Abstract
An abrasive article and methods for making such abrasive articles, including coated and nonwoven abrasive articles, comprising (a) a plurality of abrasive particles and (b) a bond system which adheres the plurality of abrasive particles together, the bond system comprising a binder; the binder being formed from a binder precursor essentially free of organic solvent, the binder precursor comprising a blend of an urea-aldehyde resin and a water dilutable resole phenolic resin, the blend being catalyzed by an acid catalyst system and, in particular, a coated abrasive comprising (a) a backing having a major surface, (b) a plurality of abrasive particles, and (c) a bond system which adheres the plurality of abrasive particles to the major surface of the backing, the bond system comprising a binder; the binder being formed from a binder precursor comprising a blend of an urea-aldehyde resin and a water dilutable resole phenolic resin, the blend being catalyzed by an acid catalyst, wherein the blend comprises from about 5 to about 90 weight percent of the water dilutable resole phenolic resin and from about 95 to about 10 weight percent of the urea-aldehyde resin.
78 Citations
29 Claims
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1. An abrasive article comprising
(a) a plurality of abrasive particles and (b) a bond system which adheres the plurality of abrasive particles together, the bond system comprising a binder; the binder being formed from a binder precursor essentially free of organic solvent, the binder precursor comprising a blend of an urea-aldehyde resin and a water dilutable resole phenolic resin, the blend being catalyzed by an acid catalyst.
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2. A coated abrasive comprising
(a) a backing having a major surface, (b) a plurality of abrasive particles, and (c) a bond system which adheres the plurality of abrasive particles to the major surface of the backing, the bond system comprising a binder; the binder being formed from a binder precursor essentially free of organic solvent, the binder precursor comprising a blend of an urea-aldehyde resin and a water dilutable resole phenolic resin, the blend being catalyzed by an acid catalyst. - View Dependent Claims (4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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3. A nonwoven abrasive article having at least one major surface and an interior region, the nonwoven abrasive article comprising
(a) an open lofty web of organic fibers, (b) a plurality of abrasive particles, and (c) a bond system which adheres the plurality of abrasive particles to the open lofty web, the bond system comprising a binder; the binder being formed from a binder precursor essentially free of organic solvent, the binder precursor comprising a blend of an urea-aldehyde resin and a water dilutable resole phenolic resin, the blend being catalyzed by an acid catalyst.
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25. A method of making a coated abrasive article comprising:
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(a) providing a backing having at least one major surface, (b) applying a make coat precursor over the at least one major surface of the backing, (c) embedding a plurality of abrasive particles into and onto the make coat precursor, (d) at least partially curing the make coat precursor, (e) applying a size coat precursor, and (f) curing the size coat precursor; wherein at least one of the make coat precursor and the size coat precursor comprises a binder precursor comprising a blend of an urea-aldehyde resin and a water dilutable resole phenolic resin, the blend being catalyzed by an acid catalyst, the binder precursor being essentially free of an organic solvent. - View Dependent Claims (26, 27, 28, 29)
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Specification