CA1186276A - Resin systems for high energy electron curable resin coated webs - Google Patents
Resin systems for high energy electron curable resin coated websInfo
- Publication number
- CA1186276A CA1186276A CA000386532A CA386532A CA1186276A CA 1186276 A CA1186276 A CA 1186276A CA 000386532 A CA000386532 A CA 000386532A CA 386532 A CA386532 A CA 386532A CA 1186276 A CA1186276 A CA 1186276A
- Authority
- CA
- Canada
- Prior art keywords
- coat
- curing
- resin
- fill
- make
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
- B24D3/20—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially organic
- B24D3/28—Resins or natural or synthetic macromolecular compounds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/001—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as supporting member
- B24D3/002—Flexible supporting members, e.g. paper, woven, plastic materials
Abstract
RESIN SYSTEMS FOR HIGH ENERGY ELECTRON CURABLE
RESIN COATED WEBS
Abstract The invention provides resin compositions which are particularly suitable for utilization in electron cured coated abrasives. The resin systems of the instant inven-tion have been devised to be particularly suitable for the backing fill of a cloth which is to form the base of a coated abrasive. The formation of a treated base cloth for coated abrasive formation by electron beam curing resins creates a product which in addition to being suitable for immediate formation into a coated abrasive by application of grain is further a product which may be stored for later use or sold to other parties that have need for a waterproof stretch-resistant cloth or that make coated abrasives with-out doing cloth finishing. The invention also encompasses the formation of electron curing resin systems which are particularly desirable for the make coat and size coat utilized in forming coated abrasives. It is within the system of the invention to utilize the electron radiation curing resins in combination with the conventional heat curing resins.
RESIN COATED WEBS
Abstract The invention provides resin compositions which are particularly suitable for utilization in electron cured coated abrasives. The resin systems of the instant inven-tion have been devised to be particularly suitable for the backing fill of a cloth which is to form the base of a coated abrasive. The formation of a treated base cloth for coated abrasive formation by electron beam curing resins creates a product which in addition to being suitable for immediate formation into a coated abrasive by application of grain is further a product which may be stored for later use or sold to other parties that have need for a waterproof stretch-resistant cloth or that make coated abrasives with-out doing cloth finishing. The invention also encompasses the formation of electron curing resin systems which are particularly desirable for the make coat and size coat utilized in forming coated abrasives. It is within the system of the invention to utilize the electron radiation curing resins in combination with the conventional heat curing resins.
Description
RESIN SYSTEMS FOR HIGH ENERGY ELECTRON CURABLE
RESIN COATED WEBS
Background of the Invention 1. Field of the Invention The invention relates to coated abrasives formation.
The invention particularly relates to materials and methods ~or the formation of coated abrasive materials and the curing of backing coats on cloth or paper which will be used for ~ormation of coated abrasives.
RESIN COATED WEBS
Background of the Invention 1. Field of the Invention The invention relates to coated abrasives formation.
The invention particularly relates to materials and methods ~or the formation of coated abrasive materials and the curing of backing coats on cloth or paper which will be used for ~ormation of coated abrasives.
2. Prior Practices It is known in the coated abrasive art to apply resinous binder and abrasive grains to a paper or cloth substrate which is cured yielding sufficient strength ~or the following applications, subsequently the size coat ls applied and the product completely cured. Suitable binders are for example glutelin glue, phenolic resins andg i~ water-proof papers are desired, polyurethane resins, epoxy resins and alkyd resins, possibly in combination with melamine resinsO
Special requirements as related to technlque, apparatus and time are necessary for the curing process. To avoid destruc-tion of the substrates usually consistlng of polyester or cellulose, curing should be effected at a maxlmum temperature o~ 120 to 130C. Rapid curing allowing for the use of a horizontal dryer is difficult~ because o~ the formation of gas bubbles affecting the adhesion of the resin on the substrate. Drying o~ the coated material generally requires one or several hours, and is there~ore carried out in a loop dryer. The 1GOP dryers through which the coated web material ls passing, enable a long drying process, but there are also ~ ~&~27~
disadvantages, such as the formation Or de~ects where the material is suspended, sagging Or the binder and changing of the grain position due to the vertical suspension, variation Or temperature and the resulting inconsistent crosslinking of the binder produced by the necessary slow air circulation.
There are several disadvantages of the predominant commercial practice of forming coated abrasives. There are several curing steps in the typical process for formation of cloth-backed abrasives. The ma~or areas of production may be considered as first the cloth treatment to prepare the base cloth ~or application of abrasives and second the making o~ the coated abrasives using the previously prepared base cloth. I'he base cloth is coated with at least one backing coat of resin which impregnates the cloth with resin and fills interstices in the back of the cloth. The backing cloth is also coated with at least one face coat that fills interstices of the cloth on the side where abrasive grain is placed. The ~ace coat or coats of the backing cloth also aid in adhesion of the coat containing the grains onto the cloth.
The second ma~or area of coated abrasive drying is the drying of the make coat which contains the grain and curing the size coat which ls an overcoat placed onto the coated abrasive after the grain is at least partially adhered onto the backing by the make coat. In some instances, pre-size coat(s) are applied prior to the make coat~ The drying of the presize make and size coats as set forth above generally is done in a lengthy loop dryer that requires a tremendous amount of floor space and energy. Further the larger dryers where the curing takes place over a long period are difficult to completely control for accurate temperature. There also is the problem of the resin and grain shiftlng positions during curlng because of the long hang times in the uncured form.
It has been suggested in the ~Jnited States Pa~ent No.
4,047,903, Hesse et al, that the ~ormation of coated abrasives be carried out with at least one layer of resin being cured by electron beam, However, there has remained a need for apparatus which would allow the commercial exploitation of electron beam curing. Hesse et al does not set forth apparatus that would allow the continuous formation of coated abrasives. There are extensive difficulties in commercial exploitation of electron beam curing. Selection oE
resins suitable for electron beam curing of all resin coats utilized in formation of coated abrasives is difficult.
When forming coated abrasives, normally relatively thick coats of resin compared with prior uses of the electron beam are utilized. The resins necessary also are very sticky prior to being completely cured. Therefore, multiple path systems such as disclosed in some prior electron beam curing systems such as United States Patent No. 3,022,543 are not satisfactory since if the resins touch a roller the system usually will gum-up and not perfor~.
Therefore, there remains a need for a system of electron beam curing resins which will allow formation of good quality coated abrasives in a low-cost commercially satisfactory manner.
According to one aspect of the present invention, a method of forming a backing material for a coated abrasive comprising providing a fibrous backing material, coating the backing material on one side with a resin system comprising an epoxy acrylate, a pyrrolidone derivative and an inorganic filler, to form a face fill coat, curing said face fill coat by exposure to electron radiation, applying a back fill coat to the opposite side of said fibrous material, wherein said back fill composition comprises an epoxy acrylate resin, a pyrrolidone derivative and an inorganic filler and curing said back fill by exposure to an electron radiation source, 1 l~ti~ o ~
~ ccorcling to a Eurther aspect v~ the present invention, a method of forming a coated abrasive comprising providiny a fibrous backing material, coating the back:ing material on one side with a resin system comprising an epoxy acrylate, a pyrrolidone derivative and an inorganic filler, to Eorm a face fill coat, curing said Eace fill coat by exposure to electron radiation, applying a back fill coat to the opposite side of said fibrous material, wherein said back fill composition comprises an epoxy acrylate resin, a pyrrolidone derivative and an inorganic filler, curing said back fill by exposure to an electron radiation source, applying a make coat over the face coat wherein said make coat comprises an expoxy acrylate resin, a pyrrolidone derivative and an inorganic filler, applying abrasive grain material to said make coat, exposing said make coat having embedded therein the abrasive grain material to a curing amount of electron radiation, applying a size coat over the abrasive grain and make coat wherein said size coat comprises an epoxy acrylate resin, a pyrrolidone derivative, an acrylic acid derivative and inorganic filler and curing said wet size coat by exposure to a source of electron radiation to cure said size coat.
The resin compositions which are provided are particularly suitable for utilization in electron cured coated ~,~r~, L&~;~7~
abrasives. The resin systems of the lnstant invention have been devised to be particularly suitable ~or the backing fill of a cloth which is to form the base of a coated abrasive.
The formation of a treated base cloth for coated abrasive ~ormation by electron beam curing resins creates a product which in addition to being suitable for immediate formation into a coated abrasive by application of grain is further a product which may be stored for later use or sold to other parties that have need ~or a waterproof stretch~resistant cloth or that make coated abrasives without doing cloth finishing.
The invention also encompasses the formation o~ electron curing resin systems which are particularly desirable for the make coat utilized in forming coated abrasives. The make coat is th`e resin coat onto which the abrasive grain is deposited. The make coat must be such as to hold the grain in the resin during use while the belt is flexed numerous times without the coat becoming dislodged from the base cloth or the grain becoming dislodged from the resin layer.
Another feature of this invention is that a novel size coat resin system for high energy electron curing has been devised.
The size coat is the coat which is placed over the grain of an abrasive to aid in holding the abrasive grains onto the base cloth during flexing and grinding operations.
It is within the sys~em of the invention to utilize the electron radiation curing resins in combination with the conventional heat curing resins. For instance~ the back and ~ace coats of the cloth could be formed by electron beam curing and then the make and size coats formed utiliæing conventional resin systems. In addition, the electron beam curing resin systems of the instant invention could be utilized with a backing cloth having the conventional heat-cured resins.
Brief Description of ~he Drawings Fig. 1 illustrates in cross section the formatlon of a coated abrasive on a cloth backing material.
Fig. 2 is a sectional view of a coated abrasive on a paper-backing material.
Detailed Description of the Invention The resin systems of the instant invention provide advantages over prior systems. The electron radiation curing resin systems for the make and siæe coat of the coated abrasives provide more uniform resin coats and allow rapid curing with little time for shifting of the resin grain prior to cure. Further, the system is advantageous in a savings of space and labor requlred in performing the operations o~ coated abrasive manufacture. The treating of cloth, paper or like backing materials to prepare them for use as coated abrasives base or for use as a base ~or other coating processes.
The resin systems o~ the invention may be utilized to ~orm either cloth-backed or paper-backed resin treated sheet materials. The resin systems further may be used to prov~de resin-treated flexible webs of cloth or paper that may be sold for others to use in coated abrasive manufacture.
Coated abrasives such as may be produced by resin systems o~ the invent:lon are illustrated in cross-section in 2~ Figs. 1 and 2. As illustrated in Fig~ 1, the coated abrasive generally indicated as 30 is cloth backed. Cloth 42 has been treated with a back coat 40 and a ~ace coat 38.
Overlaying the face coat is a make coat 36 in which are embedded abrasives 32 such as silicon carbide and aluminum oxide. A ~ize coat 34 has been placed over the make coat 36 and the abrasive grains 32. There is no clear line of 7~i demarcation between the back coat and the race coat which meet in the interior of the cloth backing which is saturated as much as possible wi~h the resins of these coats.
In Fig. 2 there is illustr~ted a coated abrasive ~enerally indicated as 50 which ls formed on a paper backing 60. Paper backing 60 is treated with a back coat 58 and a face coat 5~. The face coat is overcoated ~ith a make coat 54 in which are embedded abrasive grains 62. The abrasive grains 62 and make coat 54 are overcoated with a size coat 52 which aids in holding the abrasive grains 62 onto the backing during utilization and further may contain cutting aids. The order in which the back coat and face coat are placed onto the substrate may be varied, but generally the ~ace coat is placed onto the substrate ~irst. Each of the back coat, face coat, make coat and size coat is cured prior to being overcoated with additional resin systems.
The electron radiation curable resin systems of the invention generally in each case comprise an oligomer, a diluent, fillers and minor amounts of other additives, such as surfactants, pigments and suspending agents. The amounts and specific material are selected in each case to give the desired properties and lowest cost ~or each coat.
The oligomers used in the systems of the invention may be any reactive polymer which gives the desired properties to the backing material and coated abrasive materials.
Suitable electron-curable materials have been ~ound to be the urethane-acrylates, and epoxy acrylates. Particularly preferred among the acrylated epoxies are the diacrylate esters such as the diacrylate esters of bisphenol A epoxy resin Preferred urethanes are diacrylate e~ters of a hydroxy terminated NC0 extended polyesters or polyethers, as these resins have good strength properties and adhere well to both the base materials and the abrasi~e grain. The ~6Z'76 urethane acrylates find best use in cloth treatment systems and waterproof cloth make coat as they are less hard than the epoxy acrylates.
In addition to the oligomers, diluents are utilized.
The diluents are utilized to adJust the viscosity so as to be suitable for the various application methods such as kni~e coating, roll pressure coating, transfer rolls and doctor blades. Further, the diluents modify curing proper-ties and modify the flexibility of the resin to increase or decrease flexibility for use in the coated abrasives. Any diluent suitable for advantageously modifying the properties of acrylated urethane or acrylated epoxy resins may be utilized in the invention. Among suitable diluents for the electron-curable resins are the vinyl pyrrolidones and the multi-functional and mono-functional acrylates. The pre-~erred compounds are N-vinyl-2-pyrrolidone (NVP) 9 1~ 6 hexanediol diacrylate (HDODA), tetraethylene glycol diacrylate (TTEGDA) and trimethylolpropane triacrylate (TMPTA) as these materials have been found in addition to ad~usting viscosity successfully 9 control flexibility and reduce radiation requlred for curing.
The resin systems of the invention also generally contains a filler material which may be selected ~rom any ~iller which does not harmfully effect the properties of the system, is low in cost and is able to be included in signi-ficant amounts in the system. Preferred fillers are calcium carbonate, aluminum silicate and aluminum trihydrate as these materials have been ~ound to be usable in large amounts in the resin systems with retention of good property strengths and flexibility properties Or the cured resin.
Among additlves suitable for the resin systems of the instant invention are those designed to act as surractants, pigments for colors and suspending agents. A preferred suspending agent has been found to be fumed silica, prefer-ably in about 12 mlllimicron particle size~ as such material 7~;
gives good rheological properties. Any suitable dyes orpigments may be utilized to color the coated abrasive by the desired amount.
In formation o~ both the face and back coats Or the invention, the oligomer and diluent are mixed in a ratio of about 50 to about 90~ oligomer to about 10 to about 50~
diluent. A pre~erred range of diluent has been found to be about 10 to about 30% by weight of the oligomer for desired flexibility and hardness. The amount is selected so as to give the desired viscosity for application of the oligomer by whatever method of application is utilized and also to give the required flexibility and hardness.
The amount of filler in the face and back coat is determined in respect to the mixture of oligomer and diluent.
Generally between about 30 and about 100 parts by weight of filler are utilized per 100 parts by weight of the oligomer and diluent system. The surfactant, suspending agent and pigments are generally used in very small amounts and at the minimum which is effective to give the colorant and disper-sant properties desired.
The amount of face fill necessary for each substrate isbest determined by looking to the properties desired in the final product. In the instance of 17 pound per ream polyester substrate, it has been found that between about 2~ and about 60% of the fabric weight should be applied as a face fill coat. For the same 17 pound polyester fabric, a back fill of about 10% to about 30% by weight of the polyester has been found to be suitable to produce a filled cloth Or excellent flexibility, wear and stretch resistance.
Special requirements as related to technlque, apparatus and time are necessary for the curing process. To avoid destruc-tion of the substrates usually consistlng of polyester or cellulose, curing should be effected at a maxlmum temperature o~ 120 to 130C. Rapid curing allowing for the use of a horizontal dryer is difficult~ because o~ the formation of gas bubbles affecting the adhesion of the resin on the substrate. Drying o~ the coated material generally requires one or several hours, and is there~ore carried out in a loop dryer. The 1GOP dryers through which the coated web material ls passing, enable a long drying process, but there are also ~ ~&~27~
disadvantages, such as the formation Or de~ects where the material is suspended, sagging Or the binder and changing of the grain position due to the vertical suspension, variation Or temperature and the resulting inconsistent crosslinking of the binder produced by the necessary slow air circulation.
There are several disadvantages of the predominant commercial practice of forming coated abrasives. There are several curing steps in the typical process for formation of cloth-backed abrasives. The ma~or areas of production may be considered as first the cloth treatment to prepare the base cloth ~or application of abrasives and second the making o~ the coated abrasives using the previously prepared base cloth. I'he base cloth is coated with at least one backing coat of resin which impregnates the cloth with resin and fills interstices in the back of the cloth. The backing cloth is also coated with at least one face coat that fills interstices of the cloth on the side where abrasive grain is placed. The ~ace coat or coats of the backing cloth also aid in adhesion of the coat containing the grains onto the cloth.
The second ma~or area of coated abrasive drying is the drying of the make coat which contains the grain and curing the size coat which ls an overcoat placed onto the coated abrasive after the grain is at least partially adhered onto the backing by the make coat. In some instances, pre-size coat(s) are applied prior to the make coat~ The drying of the presize make and size coats as set forth above generally is done in a lengthy loop dryer that requires a tremendous amount of floor space and energy. Further the larger dryers where the curing takes place over a long period are difficult to completely control for accurate temperature. There also is the problem of the resin and grain shiftlng positions during curlng because of the long hang times in the uncured form.
It has been suggested in the ~Jnited States Pa~ent No.
4,047,903, Hesse et al, that the ~ormation of coated abrasives be carried out with at least one layer of resin being cured by electron beam, However, there has remained a need for apparatus which would allow the commercial exploitation of electron beam curing. Hesse et al does not set forth apparatus that would allow the continuous formation of coated abrasives. There are extensive difficulties in commercial exploitation of electron beam curing. Selection oE
resins suitable for electron beam curing of all resin coats utilized in formation of coated abrasives is difficult.
When forming coated abrasives, normally relatively thick coats of resin compared with prior uses of the electron beam are utilized. The resins necessary also are very sticky prior to being completely cured. Therefore, multiple path systems such as disclosed in some prior electron beam curing systems such as United States Patent No. 3,022,543 are not satisfactory since if the resins touch a roller the system usually will gum-up and not perfor~.
Therefore, there remains a need for a system of electron beam curing resins which will allow formation of good quality coated abrasives in a low-cost commercially satisfactory manner.
According to one aspect of the present invention, a method of forming a backing material for a coated abrasive comprising providing a fibrous backing material, coating the backing material on one side with a resin system comprising an epoxy acrylate, a pyrrolidone derivative and an inorganic filler, to form a face fill coat, curing said face fill coat by exposure to electron radiation, applying a back fill coat to the opposite side of said fibrous material, wherein said back fill composition comprises an epoxy acrylate resin, a pyrrolidone derivative and an inorganic filler and curing said back fill by exposure to an electron radiation source, 1 l~ti~ o ~
~ ccorcling to a Eurther aspect v~ the present invention, a method of forming a coated abrasive comprising providiny a fibrous backing material, coating the back:ing material on one side with a resin system comprising an epoxy acrylate, a pyrrolidone derivative and an inorganic filler, to Eorm a face fill coat, curing said Eace fill coat by exposure to electron radiation, applying a back fill coat to the opposite side of said fibrous material, wherein said back fill composition comprises an epoxy acrylate resin, a pyrrolidone derivative and an inorganic filler, curing said back fill by exposure to an electron radiation source, applying a make coat over the face coat wherein said make coat comprises an expoxy acrylate resin, a pyrrolidone derivative and an inorganic filler, applying abrasive grain material to said make coat, exposing said make coat having embedded therein the abrasive grain material to a curing amount of electron radiation, applying a size coat over the abrasive grain and make coat wherein said size coat comprises an epoxy acrylate resin, a pyrrolidone derivative, an acrylic acid derivative and inorganic filler and curing said wet size coat by exposure to a source of electron radiation to cure said size coat.
The resin compositions which are provided are particularly suitable for utilization in electron cured coated ~,~r~, L&~;~7~
abrasives. The resin systems of the lnstant invention have been devised to be particularly suitable ~or the backing fill of a cloth which is to form the base of a coated abrasive.
The formation of a treated base cloth for coated abrasive ~ormation by electron beam curing resins creates a product which in addition to being suitable for immediate formation into a coated abrasive by application of grain is further a product which may be stored for later use or sold to other parties that have need ~or a waterproof stretch~resistant cloth or that make coated abrasives without doing cloth finishing.
The invention also encompasses the formation o~ electron curing resin systems which are particularly desirable for the make coat utilized in forming coated abrasives. The make coat is th`e resin coat onto which the abrasive grain is deposited. The make coat must be such as to hold the grain in the resin during use while the belt is flexed numerous times without the coat becoming dislodged from the base cloth or the grain becoming dislodged from the resin layer.
Another feature of this invention is that a novel size coat resin system for high energy electron curing has been devised.
The size coat is the coat which is placed over the grain of an abrasive to aid in holding the abrasive grains onto the base cloth during flexing and grinding operations.
It is within the sys~em of the invention to utilize the electron radiation curing resins in combination with the conventional heat curing resins. For instance~ the back and ~ace coats of the cloth could be formed by electron beam curing and then the make and size coats formed utiliæing conventional resin systems. In addition, the electron beam curing resin systems of the instant invention could be utilized with a backing cloth having the conventional heat-cured resins.
Brief Description of ~he Drawings Fig. 1 illustrates in cross section the formatlon of a coated abrasive on a cloth backing material.
Fig. 2 is a sectional view of a coated abrasive on a paper-backing material.
Detailed Description of the Invention The resin systems of the instant invention provide advantages over prior systems. The electron radiation curing resin systems for the make and siæe coat of the coated abrasives provide more uniform resin coats and allow rapid curing with little time for shifting of the resin grain prior to cure. Further, the system is advantageous in a savings of space and labor requlred in performing the operations o~ coated abrasive manufacture. The treating of cloth, paper or like backing materials to prepare them for use as coated abrasives base or for use as a base ~or other coating processes.
The resin systems o~ the invention may be utilized to ~orm either cloth-backed or paper-backed resin treated sheet materials. The resin systems further may be used to prov~de resin-treated flexible webs of cloth or paper that may be sold for others to use in coated abrasive manufacture.
Coated abrasives such as may be produced by resin systems o~ the invent:lon are illustrated in cross-section in 2~ Figs. 1 and 2. As illustrated in Fig~ 1, the coated abrasive generally indicated as 30 is cloth backed. Cloth 42 has been treated with a back coat 40 and a ~ace coat 38.
Overlaying the face coat is a make coat 36 in which are embedded abrasives 32 such as silicon carbide and aluminum oxide. A ~ize coat 34 has been placed over the make coat 36 and the abrasive grains 32. There is no clear line of 7~i demarcation between the back coat and the race coat which meet in the interior of the cloth backing which is saturated as much as possible wi~h the resins of these coats.
In Fig. 2 there is illustr~ted a coated abrasive ~enerally indicated as 50 which ls formed on a paper backing 60. Paper backing 60 is treated with a back coat 58 and a face coat 5~. The face coat is overcoated ~ith a make coat 54 in which are embedded abrasive grains 62. The abrasive grains 62 and make coat 54 are overcoated with a size coat 52 which aids in holding the abrasive grains 62 onto the backing during utilization and further may contain cutting aids. The order in which the back coat and face coat are placed onto the substrate may be varied, but generally the ~ace coat is placed onto the substrate ~irst. Each of the back coat, face coat, make coat and size coat is cured prior to being overcoated with additional resin systems.
The electron radiation curable resin systems of the invention generally in each case comprise an oligomer, a diluent, fillers and minor amounts of other additives, such as surfactants, pigments and suspending agents. The amounts and specific material are selected in each case to give the desired properties and lowest cost ~or each coat.
The oligomers used in the systems of the invention may be any reactive polymer which gives the desired properties to the backing material and coated abrasive materials.
Suitable electron-curable materials have been ~ound to be the urethane-acrylates, and epoxy acrylates. Particularly preferred among the acrylated epoxies are the diacrylate esters such as the diacrylate esters of bisphenol A epoxy resin Preferred urethanes are diacrylate e~ters of a hydroxy terminated NC0 extended polyesters or polyethers, as these resins have good strength properties and adhere well to both the base materials and the abrasi~e grain. The ~6Z'76 urethane acrylates find best use in cloth treatment systems and waterproof cloth make coat as they are less hard than the epoxy acrylates.
In addition to the oligomers, diluents are utilized.
The diluents are utilized to adJust the viscosity so as to be suitable for the various application methods such as kni~e coating, roll pressure coating, transfer rolls and doctor blades. Further, the diluents modify curing proper-ties and modify the flexibility of the resin to increase or decrease flexibility for use in the coated abrasives. Any diluent suitable for advantageously modifying the properties of acrylated urethane or acrylated epoxy resins may be utilized in the invention. Among suitable diluents for the electron-curable resins are the vinyl pyrrolidones and the multi-functional and mono-functional acrylates. The pre-~erred compounds are N-vinyl-2-pyrrolidone (NVP) 9 1~ 6 hexanediol diacrylate (HDODA), tetraethylene glycol diacrylate (TTEGDA) and trimethylolpropane triacrylate (TMPTA) as these materials have been found in addition to ad~usting viscosity successfully 9 control flexibility and reduce radiation requlred for curing.
The resin systems of the invention also generally contains a filler material which may be selected ~rom any ~iller which does not harmfully effect the properties of the system, is low in cost and is able to be included in signi-ficant amounts in the system. Preferred fillers are calcium carbonate, aluminum silicate and aluminum trihydrate as these materials have been ~ound to be usable in large amounts in the resin systems with retention of good property strengths and flexibility properties Or the cured resin.
Among additlves suitable for the resin systems of the instant invention are those designed to act as surractants, pigments for colors and suspending agents. A preferred suspending agent has been found to be fumed silica, prefer-ably in about 12 mlllimicron particle size~ as such material 7~;
gives good rheological properties. Any suitable dyes orpigments may be utilized to color the coated abrasive by the desired amount.
In formation o~ both the face and back coats Or the invention, the oligomer and diluent are mixed in a ratio of about 50 to about 90~ oligomer to about 10 to about 50~
diluent. A pre~erred range of diluent has been found to be about 10 to about 30% by weight of the oligomer for desired flexibility and hardness. The amount is selected so as to give the desired viscosity for application of the oligomer by whatever method of application is utilized and also to give the required flexibility and hardness.
The amount of filler in the face and back coat is determined in respect to the mixture of oligomer and diluent.
Generally between about 30 and about 100 parts by weight of filler are utilized per 100 parts by weight of the oligomer and diluent system. The surfactant, suspending agent and pigments are generally used in very small amounts and at the minimum which is effective to give the colorant and disper-sant properties desired.
The amount of face fill necessary for each substrate isbest determined by looking to the properties desired in the final product. In the instance of 17 pound per ream polyester substrate, it has been found that between about 2~ and about 60% of the fabric weight should be applied as a face fill coat. For the same 17 pound polyester fabric, a back fill of about 10% to about 30% by weight of the polyester has been found to be suitable to produce a filled cloth Or excellent flexibility, wear and stretch resistance.
3 The amount of the make and size coats applied to the substrate is whatever is sufficient to hold the abrasive particles.
7~
The methods Or applying the coatings Or the lnvention may be selected ~rom those conventional in the coated abra-sive art. Among typical methods are roll coating rrom a transfer roll and doctor blade coating. A preferred method has been round to be press roll or direct roll coating as this is easy to control.
In the siæe coat, actlve flllers may be utilized that aid in cutting. Among such rlllers for utilization in the size coat are cryolite cutting aids whlch lncrease the llfe o~ the abrasive~ Typical other cutting aids are potassium fluroborate, feldspar, sulfur and iron pyrites.
The amount Or radiation from an electron radiation source utllized to cure the instant resin systems is selected to provide complete cure. First coats may not need complete cure. A cure Or the back and ~ace coats at 300 kllovolts ror a 1 megarad dose to provide surficient cure with applica-tion o~ the radiation directly onto the wet surface. The make and size coats for the resln systems o~ the invention at the about 20 mils thickness utilized have been ~ound to be sufriclently cured at ~00 kilovolts for a 5 megarads dose from either the ~ace or through the backing. Thè total voltage requirement is regulated to vary the depth o~
penetration of the electron beam or other electron radiatlon source.
The resin systems of the instant invention may be utillzed for coating with any suitable source o~ electron radiation and coating apparatus. A suitable apparatus is disclosed in copending and coassigned application entitled APPARATUS FOR ELECTRON CURING OF RESIN COATED WEBS, inventor 30 Alton Miller, riled as Serial No. 382,414 on July 23, 1981.
The rollowing examples illustrate the formation Or a coated abraslve in accordance with preferred ~orms Or the lnstant inventlon. Parts and percenta~es are by weight . . . i.~
unless otherwise indic4ted. A ream as utilized in the description and Examples is 4Bo sheets of 9 lnches by 11 inches.
EXAMPLES
Example 1 This Example will illustrate the formation of a coated abrasive utilizing the EB cured reslns of the lnvention in each coat of the abrasive and backing material.
There is provlded a sateen polyester cloth in a weave o~ 103 x ll0. This means that there are 103 threads per inch in the running direction and 40 threads per inch in the crosslng clirection. The polyester had been heat treated to provide a ~abric with very low shrink and stretch properties.
A ~ace fill coating was applied to the cloth side with the predominance of fill threads. The face ~ill ingredients were as ~ollows:
CLASS COMPOSITION AMOUNT
Ollgomer Acrylated-urethane (Uvithane~
783 Thikol Corporation) 4064 grams 20 Diluent N-vinyl-2-pyrrolidone 3800 grams Filler calcium carbonate o~ specific gravity of about 2.74 with an average particle size of between about 17 and about 25 microns as measured at the 50% point on a sedimentation curve. Not over 35% by weight remaining on a 270 mesh screen having an opening o~
53 microns. 3600 grams 30 Surfactant ethoxylated alkyphenol (Igepal~
surfactant GAF Corporation~ 56 grams Suspending agent ~umed slllca (Aerosil 200) 60 grams Colorant red pigment (P.D.I. 1501) 10 grams Pigment Dispersions Inc.
2'7~;
The face fill coating was applled to a continuous pclyester material o~ 17 pounds per ream welght as set forth above by a knife at a rate of about 11 pounds per ream in a cont~nuous coating and electron beam curing devlce such as illustrated in the above-re~erenced copending applicatlon Serial No. 392,414 riled July 23, 1981, entitled APPARATUS
FOR ELECTRON CURING OF RESIN COATED WE~S, which has been incorporated by reference. The layer is partially cur~ed to a non-tacky state at about 300 kilovolts at a speed of about 20 fee,t per minute for a megarad dose Or 0.8 megarads.
After the ~ace rlll was partially cured, the cloth having the cured ~ace fill coat was repositloned ror appli-cation of a back fill coat. The back filled coat had a radiation curable resin system coating as ~ollows: ' 15 CLASS COMPOSITION AM~UNT
Oligomer diacrylate ester of a bisphenol A type epoxy resin (Celrad~ 3600 Celanese Chemical Co.) 2000 grams Diluent N-vinyl-2-pyrrolidone 2000 grams trimethylolpropane triacrylate ITMPTA) 780 grams Filler calclum carbonate (same as in : face fill) 5000 grams Surfactant FC430 (Florocarbon ~rom 3M Company) 10 grams Colorants brown (PDI 1705) 500 grams black ~PDI 1800) 50 grams from Pigment Disperslons Inc.
Suspending Agent ~umed silica, Aerosil 250, average primary particle size 12 millimicron 100 grams This resin system was roll coated by direct roll application onto the back Or the previously face ~illed roll. The application rate was at a rate of about 5 pounds per ream.
35 The coating was then cured at 300 kllovolts at a speed of 20 feet per minute for an exposure of about .8 megarads. After curlng, the back and face coated cloth was removed and again placed in the device as the dlspenslng roll.
A make coat was prepared for application to the pre-pared backing material. The make coat has the following composition-CLASS COMPOSITION AMOUNT
5 Oligomer acrylated epoxy resin (Celrad~
3500 - Celanese Chemical Co.) 5530 grams Diluents N-vinyl 2-pyrrolidone 1273 grams isobornyl acrylate available from Rohm and Haas Company as Monomer QM-589 1661 grams acrylic acid 288 grams Filler calcium carbonate (same composi-tion as in the face fill coat) 4000 grams 15 Surfactant FC-430 fluorocarbon 10 grams Suspending agent Aerosil 200 150 grams Colorants red pigment (P.D.I. 1501 Pigment Dispersions~
Inc.) 270 grams The make coat was applied at a rate of about 15.7 pounds per ream at an application speed of about 20 feet per minute.
The grain was applied at a rate of about 72 pounds per ream using alumina grain of particle size 36 grit. The curing was carried out at 500 kilovolts to give a treatment of about 5 megarads. Cure was carried out by electron beam through the backing rather than directly onto the grain.
The backing having the make coat and abrasive grain thereon was removed and placed in position ~or application of the 3 siæe coat.
The size coat of the following composition was prepared for application onto the make coat and ~rain.
CLASS COMPOSITION AMOUNT
.
Oligomer Celrad~ 3600 (further identified in the back coaL listing above) 5210 grams Diluent isobornyl acrylate (rurther identified in the make coat lis~ing above)1500 grams NVP (further identified in the face fill listing above) 1500 grams TMPTA (further identified in the li5ting under back fill above) 1000 grams Filler calcium carbonate (further identified in the face fill listing above) filler 15 Cutting aid cryolite (95% through 325 U.S.
mesh screen all through 100 U.S. mesh) 8000 grams Suspending agent Aerosil 200 100 grams 20 Pigment black pigment (Pigment Dispersion Inc~
P.D.I. 1800) 100 grams The size coat was cured at 50G kilovolts at a speed of approximately 20 feet per minute past the electron beam.
The curing dose was about 5 megarads dose from the face side.
The abrasive material was tested and found to provide coatin~ performance at least equal to the presently avail-able alumina abrasives formed on the same polyester backing material.
Example 2 The polyester backing ma~erial having a face fill and back ~ill coat as formed in Example 1 is utilized to form a coated abrasive utilizing conventional waterproor heat curable make and size coats. The make ~oat is of the compo-sition:
2'7G
CLASS COMPOSITION AMOUNT
Phenolic Resin Phenol-formaldehyde resole 550 cps. at 70% solids 10,000 grams Filler Calcium carbonate (same as Example 1) 10~000 grams The size coat is of a conventional he~t curing resin:
CLASS COMPOSITION AMOUNT
Phenolic Resin Phenol-formaldehyde resole 500 cps. at 70% solids 8,100 grams 10 Cutting Aid Cryolite (same as Example 1) 9,900 grams Pigment Carbon black dispersion 100 grams This product exhibits good coated abrasive properties, comparable with the conventional products.
Exam~le 3 The process of Example 1 was repeated except that the back fill coat was formed utilizing a conventional heat curable acrylic latex resin formed of 70 parts of heat curable latex (Rohm & Haas AC 604 - 46% latex solids) and 30 parts calcium carbonate ~same composition as Example 1).
The product was a satisfactory coated abrasive with good cutking and life propertiesO
Example 4 The process of Example 1 was repeated except that a heat curing make coat of phenolic resin composition below was substituted for the electron beam curable coat of Example 1.
CLASS COMPOSITION AMOUNT
._ Phenolic Resin Phenol-formaldehyde resole 550 cps. at 70% solids 10,000 grams Filler Calcium carbonate (same as Example 1) 10,000 grams A satisfactory coated abrasive was produced.
Example 5 The Example of Example 1 was repeated except that a heat curing ize coat composition as below was substituted for the electron beam curing size coat of Example 1.
CLASS COMPOSITION AMOUNT
_.. ... .
Phenolic Resin Phenol-~ormaldehyde resole 500 cps. at 70% solids 8,100 grams Cutting Aid Cryolite (same as Example 1) 9,900 grams 15 Pigment Carbon black dispersion 100 grams A satisfactory coated abraslve material was produced.
It is understood that the above-described embodiments - are simply illustrative of the invention and that many other embodiments can be devised without departing from the spirit 20 and scope of the invention. For instance, the amount Or the electron radlation curing resins applied to the coated abrasive material may be changed depending on the backing material and intended use of the abrasive. Further, while the invention has been illustrated with specific acrylated-25 urethane and acrylated epoxy resins as the oligomers, thereare numerous other acrylated epoxies and electron beam curing acrylated-urethanes which could be ut~lized in the instant invention. Further, while the diluents have been illustrated as acrylates of specific composition, there are 30 other acrylates which could be utilized lf desired to give polymers Or different hardness. Although~ the resin systems of the lnvention have been found to be particularly suitable ror use in comblnatlon with each other, the systems of the '7~;
invention may be utili~ed in combination with conventionally cured coatings or with other e]ectron beam cured coatings.
Further, other additlves could be inserted lnto the system without detrimentally affecting the invention. For instance, viscosity controlling agents3 anti-foaming agents or other colorants could be utilized. Further, it would be within the scope of the invention to in the instance of a base other than polyester, to utilize adhesion promoters with a particular substrate in the face, size and backing layers such as silanes materials to promote the adhesion to fiber-glass backings.
While the invention has been described with specific embodiments, there are modifications that may be made without departing from the spirit of the invention. For instance, the method of c~oating could be changed to coat all layers as transfer roll or doctor roll. Further, another change within the invention would be to cure the coatings from either the ~et resin side or application of the electron beam through the backing to cure the resin. Further, while the cloth treatment steps have been specifically illustrated by the use of the cloth material in coated abrasives, there are other uses of such materials such as in forming artifi-cial leathers, waterproof fabrics for tents and boats and filled fabrics that are utilized for vapor barriers. The scope of the invention is not ~o be limited by specific illustrates 2 but is defined by the claims.
7~
The methods Or applying the coatings Or the lnvention may be selected ~rom those conventional in the coated abra-sive art. Among typical methods are roll coating rrom a transfer roll and doctor blade coating. A preferred method has been round to be press roll or direct roll coating as this is easy to control.
In the siæe coat, actlve flllers may be utilized that aid in cutting. Among such rlllers for utilization in the size coat are cryolite cutting aids whlch lncrease the llfe o~ the abrasive~ Typical other cutting aids are potassium fluroborate, feldspar, sulfur and iron pyrites.
The amount Or radiation from an electron radiation source utllized to cure the instant resin systems is selected to provide complete cure. First coats may not need complete cure. A cure Or the back and ~ace coats at 300 kllovolts ror a 1 megarad dose to provide surficient cure with applica-tion o~ the radiation directly onto the wet surface. The make and size coats for the resln systems o~ the invention at the about 20 mils thickness utilized have been ~ound to be sufriclently cured at ~00 kilovolts for a 5 megarads dose from either the ~ace or through the backing. Thè total voltage requirement is regulated to vary the depth o~
penetration of the electron beam or other electron radiatlon source.
The resin systems of the instant invention may be utillzed for coating with any suitable source o~ electron radiation and coating apparatus. A suitable apparatus is disclosed in copending and coassigned application entitled APPARATUS FOR ELECTRON CURING OF RESIN COATED WEBS, inventor 30 Alton Miller, riled as Serial No. 382,414 on July 23, 1981.
The rollowing examples illustrate the formation Or a coated abraslve in accordance with preferred ~orms Or the lnstant inventlon. Parts and percenta~es are by weight . . . i.~
unless otherwise indic4ted. A ream as utilized in the description and Examples is 4Bo sheets of 9 lnches by 11 inches.
EXAMPLES
Example 1 This Example will illustrate the formation of a coated abrasive utilizing the EB cured reslns of the lnvention in each coat of the abrasive and backing material.
There is provlded a sateen polyester cloth in a weave o~ 103 x ll0. This means that there are 103 threads per inch in the running direction and 40 threads per inch in the crosslng clirection. The polyester had been heat treated to provide a ~abric with very low shrink and stretch properties.
A ~ace fill coating was applied to the cloth side with the predominance of fill threads. The face ~ill ingredients were as ~ollows:
CLASS COMPOSITION AMOUNT
Ollgomer Acrylated-urethane (Uvithane~
783 Thikol Corporation) 4064 grams 20 Diluent N-vinyl-2-pyrrolidone 3800 grams Filler calcium carbonate o~ specific gravity of about 2.74 with an average particle size of between about 17 and about 25 microns as measured at the 50% point on a sedimentation curve. Not over 35% by weight remaining on a 270 mesh screen having an opening o~
53 microns. 3600 grams 30 Surfactant ethoxylated alkyphenol (Igepal~
surfactant GAF Corporation~ 56 grams Suspending agent ~umed slllca (Aerosil 200) 60 grams Colorant red pigment (P.D.I. 1501) 10 grams Pigment Dispersions Inc.
2'7~;
The face fill coating was applled to a continuous pclyester material o~ 17 pounds per ream welght as set forth above by a knife at a rate of about 11 pounds per ream in a cont~nuous coating and electron beam curing devlce such as illustrated in the above-re~erenced copending applicatlon Serial No. 392,414 riled July 23, 1981, entitled APPARATUS
FOR ELECTRON CURING OF RESIN COATED WE~S, which has been incorporated by reference. The layer is partially cur~ed to a non-tacky state at about 300 kilovolts at a speed of about 20 fee,t per minute for a megarad dose Or 0.8 megarads.
After the ~ace rlll was partially cured, the cloth having the cured ~ace fill coat was repositloned ror appli-cation of a back fill coat. The back filled coat had a radiation curable resin system coating as ~ollows: ' 15 CLASS COMPOSITION AM~UNT
Oligomer diacrylate ester of a bisphenol A type epoxy resin (Celrad~ 3600 Celanese Chemical Co.) 2000 grams Diluent N-vinyl-2-pyrrolidone 2000 grams trimethylolpropane triacrylate ITMPTA) 780 grams Filler calclum carbonate (same as in : face fill) 5000 grams Surfactant FC430 (Florocarbon ~rom 3M Company) 10 grams Colorants brown (PDI 1705) 500 grams black ~PDI 1800) 50 grams from Pigment Disperslons Inc.
Suspending Agent ~umed silica, Aerosil 250, average primary particle size 12 millimicron 100 grams This resin system was roll coated by direct roll application onto the back Or the previously face ~illed roll. The application rate was at a rate of about 5 pounds per ream.
35 The coating was then cured at 300 kllovolts at a speed of 20 feet per minute for an exposure of about .8 megarads. After curlng, the back and face coated cloth was removed and again placed in the device as the dlspenslng roll.
A make coat was prepared for application to the pre-pared backing material. The make coat has the following composition-CLASS COMPOSITION AMOUNT
5 Oligomer acrylated epoxy resin (Celrad~
3500 - Celanese Chemical Co.) 5530 grams Diluents N-vinyl 2-pyrrolidone 1273 grams isobornyl acrylate available from Rohm and Haas Company as Monomer QM-589 1661 grams acrylic acid 288 grams Filler calcium carbonate (same composi-tion as in the face fill coat) 4000 grams 15 Surfactant FC-430 fluorocarbon 10 grams Suspending agent Aerosil 200 150 grams Colorants red pigment (P.D.I. 1501 Pigment Dispersions~
Inc.) 270 grams The make coat was applied at a rate of about 15.7 pounds per ream at an application speed of about 20 feet per minute.
The grain was applied at a rate of about 72 pounds per ream using alumina grain of particle size 36 grit. The curing was carried out at 500 kilovolts to give a treatment of about 5 megarads. Cure was carried out by electron beam through the backing rather than directly onto the grain.
The backing having the make coat and abrasive grain thereon was removed and placed in position ~or application of the 3 siæe coat.
The size coat of the following composition was prepared for application onto the make coat and ~rain.
CLASS COMPOSITION AMOUNT
.
Oligomer Celrad~ 3600 (further identified in the back coaL listing above) 5210 grams Diluent isobornyl acrylate (rurther identified in the make coat lis~ing above)1500 grams NVP (further identified in the face fill listing above) 1500 grams TMPTA (further identified in the li5ting under back fill above) 1000 grams Filler calcium carbonate (further identified in the face fill listing above) filler 15 Cutting aid cryolite (95% through 325 U.S.
mesh screen all through 100 U.S. mesh) 8000 grams Suspending agent Aerosil 200 100 grams 20 Pigment black pigment (Pigment Dispersion Inc~
P.D.I. 1800) 100 grams The size coat was cured at 50G kilovolts at a speed of approximately 20 feet per minute past the electron beam.
The curing dose was about 5 megarads dose from the face side.
The abrasive material was tested and found to provide coatin~ performance at least equal to the presently avail-able alumina abrasives formed on the same polyester backing material.
Example 2 The polyester backing ma~erial having a face fill and back ~ill coat as formed in Example 1 is utilized to form a coated abrasive utilizing conventional waterproor heat curable make and size coats. The make ~oat is of the compo-sition:
2'7G
CLASS COMPOSITION AMOUNT
Phenolic Resin Phenol-formaldehyde resole 550 cps. at 70% solids 10,000 grams Filler Calcium carbonate (same as Example 1) 10~000 grams The size coat is of a conventional he~t curing resin:
CLASS COMPOSITION AMOUNT
Phenolic Resin Phenol-formaldehyde resole 500 cps. at 70% solids 8,100 grams 10 Cutting Aid Cryolite (same as Example 1) 9,900 grams Pigment Carbon black dispersion 100 grams This product exhibits good coated abrasive properties, comparable with the conventional products.
Exam~le 3 The process of Example 1 was repeated except that the back fill coat was formed utilizing a conventional heat curable acrylic latex resin formed of 70 parts of heat curable latex (Rohm & Haas AC 604 - 46% latex solids) and 30 parts calcium carbonate ~same composition as Example 1).
The product was a satisfactory coated abrasive with good cutking and life propertiesO
Example 4 The process of Example 1 was repeated except that a heat curing make coat of phenolic resin composition below was substituted for the electron beam curable coat of Example 1.
CLASS COMPOSITION AMOUNT
._ Phenolic Resin Phenol-formaldehyde resole 550 cps. at 70% solids 10,000 grams Filler Calcium carbonate (same as Example 1) 10,000 grams A satisfactory coated abrasive was produced.
Example 5 The Example of Example 1 was repeated except that a heat curing ize coat composition as below was substituted for the electron beam curing size coat of Example 1.
CLASS COMPOSITION AMOUNT
_.. ... .
Phenolic Resin Phenol-~ormaldehyde resole 500 cps. at 70% solids 8,100 grams Cutting Aid Cryolite (same as Example 1) 9,900 grams 15 Pigment Carbon black dispersion 100 grams A satisfactory coated abraslve material was produced.
It is understood that the above-described embodiments - are simply illustrative of the invention and that many other embodiments can be devised without departing from the spirit 20 and scope of the invention. For instance, the amount Or the electron radlation curing resins applied to the coated abrasive material may be changed depending on the backing material and intended use of the abrasive. Further, while the invention has been illustrated with specific acrylated-25 urethane and acrylated epoxy resins as the oligomers, thereare numerous other acrylated epoxies and electron beam curing acrylated-urethanes which could be ut~lized in the instant invention. Further, while the diluents have been illustrated as acrylates of specific composition, there are 30 other acrylates which could be utilized lf desired to give polymers Or different hardness. Although~ the resin systems of the lnvention have been found to be particularly suitable ror use in comblnatlon with each other, the systems of the '7~;
invention may be utili~ed in combination with conventionally cured coatings or with other e]ectron beam cured coatings.
Further, other additlves could be inserted lnto the system without detrimentally affecting the invention. For instance, viscosity controlling agents3 anti-foaming agents or other colorants could be utilized. Further, it would be within the scope of the invention to in the instance of a base other than polyester, to utilize adhesion promoters with a particular substrate in the face, size and backing layers such as silanes materials to promote the adhesion to fiber-glass backings.
While the invention has been described with specific embodiments, there are modifications that may be made without departing from the spirit of the invention. For instance, the method of c~oating could be changed to coat all layers as transfer roll or doctor roll. Further, another change within the invention would be to cure the coatings from either the ~et resin side or application of the electron beam through the backing to cure the resin. Further, while the cloth treatment steps have been specifically illustrated by the use of the cloth material in coated abrasives, there are other uses of such materials such as in forming artifi-cial leathers, waterproof fabrics for tents and boats and filled fabrics that are utilized for vapor barriers. The scope of the invention is not ~o be limited by specific illustrates 2 but is defined by the claims.
Claims (9)
- The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows.
l. A method of forming a coated abrasive comprising providing a fibrous backing material, coating the backing material on one side with a resin system comprising an epoxy acrylate, a pyrrolidone derivative and an inorganic filler, to form a face fill coat, curing said face fill coat by exposure to electron radiation, applying a back fill coat to the opposite side of said fibrous material, wherein said back fill composition comprises an epoxy acrylate resin, a pyrrolidone derivative and an inorganic filler, curing said back fill by exposure to an electron radiation source, applying a make coat over the face coat wherein said make coat comprises an epoxy acrylate resin, a pyrrolidone derivative and an inorganic filler, applying abrasive grain material to said make coat, exposing said make coat having embedded therein the abrasive grain material to a curing amount of electron radiation, applying a size coat over the abrasive grain and make coat wherein said size coat comprises an epoxy acrylate resin, a pyrrolidone derivative, an acrylic acid derivative and inorganic filler and curing said wet size coat by exposure to a source of electron radiation to cure said size coat. - 2. A method of forming a backing material for a coated abrasive comprising providing a fibrous backing material, coating the backing material on one side with a resin system comprising an epoxy acrylate, a pyrrolidone derivative and an inorganic filler, to form a face fill coat, curing said face fill coat by exposure to electron radiation, applying a back fill coat to the opposite side of said fibrous material, wherein said back fill composition comprises an epoxy acrylate resin, a pyrrolidone derivative and an inorganic filler and curing said back fill by exposure to an electron radiation source.
- 3. The method of claim 2 wherein said fibrous backing material comprises a polyester cloth.
- 4 The method of claim 2 wherein said fibrous backing material comprises cotton cloth or waterproof paper.
- 5. The method of claim 2 wherein said filler comprises calcium carbonate.
- 6. The method of claim 2 wherein said filler comprises aluminum silicate or aluminum trihydrate.
- 7. The method of forming a coated abrasive comprising providing a fibrous backing material, coating the fibrous backing material on one side with a resin system comprising an epoxy acrylate, a pyrrolidone derivative and an inorganic filler to form a face fill coating, curing said face fill coating by exposure to electron radiation, applying a back fill coat to the opposite side of said fibrous backing material, wherein said back fill composition comprises an epoxy acrylate resin, a pyrrolidone derivative and an inorganic filler, curing said back fill coating by exposure to an electron radiation source, applying a make coat to the cured face fill coating, applying abrasive grain to said make coat, curing said make coat and applying a size coat over the cured make coat and abrasive and curing said size coat.
- 8. The method of claim 7 wherein said at least one of said make and size coats comprises an epoxy acrylate resin, a diluent and an inorganic filler.
- 9. The method of claim 2 wherein a heat-curable make coat of a phenolic resin is applied to said face fill coat.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US195,030 | 1980-10-08 | ||
| US06/195,030 US4457766A (en) | 1980-10-08 | 1980-10-08 | Resin systems for high energy electron curable resin coated webs |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1186276A true CA1186276A (en) | 1985-04-30 |
Family
ID=22719799
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000386532A Expired CA1186276A (en) | 1980-10-08 | 1981-09-23 | Resin systems for high energy electron curable resin coated webs |
Country Status (6)
| Country | Link |
|---|---|
| US (1) | US4457766A (en) |
| JP (1) | JPS5789565A (en) |
| CA (1) | CA1186276A (en) |
| DE (1) | DE3139813A1 (en) |
| FR (1) | FR2491377A1 (en) |
| GB (1) | GB2087263B (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109963691A (en) * | 2016-11-16 | 2019-07-02 | 3M创新有限公司 | Structured abrasive article including the feature with improved structural intergrity |
Families Citing this family (59)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4588419A (en) * | 1980-10-08 | 1986-05-13 | Carborundum Abrasives Company | Resin systems for high energy electron curable resin coated webs |
| JPS58169598A (en) * | 1982-03-26 | 1983-10-06 | 富士写真フイルム株式会社 | Production of hard sized paper |
| US5527368C1 (en) * | 1983-03-11 | 2001-05-08 | Norton Co | Coated abrasives with rapidly curable adhesives |
| US4533975A (en) * | 1983-12-27 | 1985-08-06 | North American Philips Corporation | Radiation hardenable coating and electronic components coated therewith |
| US4652274A (en) * | 1985-08-07 | 1987-03-24 | Minnesota Mining And Manufacturing Company | Coated abrasive product having radiation curable binder |
| JPH0673820B2 (en) * | 1985-11-22 | 1994-09-21 | 大日本印刷株式会社 | Abrasive material |
| CA1263240A (en) * | 1985-12-16 | 1989-11-28 | Minnesota Mining And Manufacturing Company | Coated abrasive suitable for use as a lapping material |
| US4751138A (en) * | 1986-08-11 | 1988-06-14 | Minnesota Mining And Manufacturing Company | Coated abrasive having radiation curable binder |
| US4836832A (en) * | 1986-08-11 | 1989-06-06 | Minnesota Mining And Manufacturing Company | Method of preparing coated abrasive having radiation curable binder |
| US4997717A (en) * | 1987-03-27 | 1991-03-05 | Ciba-Geigy Corporation | Photocurable abrasives |
| DE3852661D1 (en) * | 1987-03-27 | 1995-02-16 | Ciba Geigy Ag | Photo-curable abrasives. |
| US4735632A (en) * | 1987-04-02 | 1988-04-05 | Minnesota Mining And Manufacturing Company | Coated abrasive binder containing ternary photoinitiator system |
| US4828583A (en) * | 1987-04-02 | 1989-05-09 | Minnesota Mining And Manufacturing Company | Coated abrasive binder containing ternary photoinitiator system |
| CA1323949C (en) * | 1987-04-02 | 1993-11-02 | Michael C. Palazzotto | Ternary photoinitiator system for addition polymerization |
| AU621878B2 (en) * | 1988-06-02 | 1992-03-26 | Norton Company | Web with finishing coating useful as coated abrasive backing |
| US4927431A (en) * | 1988-09-08 | 1990-05-22 | Minnesota Mining And Manufacturing Company | Binder for coated abrasives |
| US4903440A (en) * | 1988-11-23 | 1990-02-27 | Minnesota Mining And Manufacturing Company | Abrasive product having binder comprising an aminoplast resin |
| US5055113A (en) * | 1988-11-23 | 1991-10-08 | Minnesota Mining And Manufacturing Company | Abrasive product having binder comprising an aminoplast resin |
| US5014468A (en) * | 1989-05-05 | 1991-05-14 | Norton Company | Patterned coated abrasive for fine surface finishing |
| US5011513A (en) * | 1989-05-31 | 1991-04-30 | Norton Company | Single step, radiation curable ophthalmic fining pad |
| US5108463B1 (en) * | 1989-08-21 | 1996-08-13 | Minnesota Mining & Mfg | Conductive coated abrasives |
| US5137542A (en) * | 1990-08-08 | 1992-08-11 | Minnesota Mining And Manufacturing Company | Abrasive printed with an electrically conductive ink |
| CA2058700C (en) * | 1991-01-08 | 2000-04-04 | David E. Williams | Polymer backed material with non-slip surface |
| JPH05318319A (en) * | 1991-10-25 | 1993-12-03 | Kansai Paint Co Ltd | Surface treating method and device for plastic raw material |
| US5178646A (en) * | 1992-01-22 | 1993-01-12 | Minnesota Mining And Manufacturing Company | Coatable thermally curable binder presursor solutions modified with a reactive diluent, abrasive articles incorporating same, and methods of making said abrasive articles |
| US5368618A (en) * | 1992-01-22 | 1994-11-29 | Minnesota Mining And Manufacturing Company | Method of making a coated abrasive article |
| US5344688A (en) * | 1992-08-19 | 1994-09-06 | Minnesota Mining And Manufacturing Company | Coated abrasive article and a method of making same |
| JPH06114747A (en) * | 1992-10-05 | 1994-04-26 | Minnesota Mining & Mfg Co <3M> | Abrasive material and its manufacturing process |
| DE69321143T2 (en) * | 1993-03-12 | 1999-03-11 | Minnesota Mining & Mfg | METHOD AND OBJECT FOR POLISHING STONE |
| US5433979A (en) * | 1993-05-17 | 1995-07-18 | Norton Company | Method of producing a non-slip sheet |
| DE69326774T2 (en) * | 1993-06-02 | 2000-06-21 | Dainippon Printing Co Ltd | GRINDING BELT AND METHOD FOR THE PRODUCTION THEREOF |
| ES2123159T3 (en) * | 1993-10-27 | 1999-01-01 | Minnesota Mining & Mfg | ABRASIVE ARTICLES INCORPORATING ADDITIONAL POLYMERIZABLE RESINS AND REAGENT THINNERS, AND METHODS TO MANUFACTURE SUCH ABRASIVE ARTICLES. |
| US5571297A (en) * | 1995-06-06 | 1996-11-05 | Norton Company | Dual-cure binder system |
| US5578343A (en) * | 1995-06-07 | 1996-11-26 | Norton Company | Mesh-backed abrasive products |
| US5571767A (en) * | 1995-08-21 | 1996-11-05 | Ferro Corporation | Low fire X7R dielectric compositions and capacitors made therefrom |
| US5854330A (en) * | 1996-03-07 | 1998-12-29 | Minnesota Mining And Manufacturing Company | Capstan comprising polyacetal-based polymer composition for magnetic tape cartridge |
| US5700302A (en) * | 1996-03-15 | 1997-12-23 | Minnesota Mining And Manufacturing Company | Radiation curable abrasive article with tie coat and method |
| DE19612771A1 (en) * | 1996-03-29 | 1997-10-02 | Basf Magnetics Gmbh | Flat composite materials suitable as abrasives or polishes |
| BR9708417A (en) * | 1996-04-02 | 1999-08-03 | Norton Co | Radiation-curable formulations |
| US5624471A (en) * | 1996-07-22 | 1997-04-29 | Norton Company | Waterproof paper-backed coated abrasives |
| US5766277A (en) * | 1996-09-20 | 1998-06-16 | Minnesota Mining And Manufacturing Company | Coated abrasive article and method of making same |
| US5730764A (en) * | 1997-01-24 | 1998-03-24 | Williamson; Sue Ellen | Coated abrasive systems employing ionizing irradiation cured epoxy resins as binder |
| US6228433B1 (en) * | 1997-05-02 | 2001-05-08 | Permagrain Products, Inc. | Abrasion resistant urethane coatings |
| US6217432B1 (en) | 1998-05-19 | 2001-04-17 | 3M Innovative Properties Company | Abrasive article comprising a barrier coating |
| US6432549B1 (en) | 1998-08-27 | 2002-08-13 | Kimberly-Clark Worldwide, Inc. | Curl-resistant, antislip abrasive backing and paper |
| US6465076B2 (en) | 1998-09-15 | 2002-10-15 | 3M Innovative Properties Company | Abrasive article with seamless backing |
| US6569602B1 (en) * | 1998-10-05 | 2003-05-27 | E. I. Du Pont De Nemours And Company | Ionization radiation imageable photopolymer compositions |
| US6239049B1 (en) | 1998-12-22 | 2001-05-29 | 3M Innovative Properties Company | Aminoplast resin/thermoplastic polyamide presize coatings for abrasive article backings |
| US6582487B2 (en) | 2001-03-20 | 2003-06-24 | 3M Innovative Properties Company | Discrete particles that include a polymeric material and articles formed therefrom |
| US6605128B2 (en) | 2001-03-20 | 2003-08-12 | 3M Innovative Properties Company | Abrasive article having projections attached to a major surface thereof |
| WO2003002484A1 (en) * | 2001-06-29 | 2003-01-09 | Crane Canada Inc. | Coating composition for a ceramic article and use in repairing defects in glazed ceramic articles |
| US6844374B2 (en) * | 2001-10-03 | 2005-01-18 | Lord Corporation | Enhanced scratch resistant coatings using inorganic fillers |
| DE10304958A1 (en) * | 2003-02-06 | 2004-08-19 | Basf Ag | Use of aqueous binders in the manufacture of abrasive materials |
| US7291658B2 (en) * | 2003-10-14 | 2007-11-06 | Ashland Licensing And Intellectual Property Llc | Radiation-curable inks for flexographic and screen-printing applications from multifunctional acrylate oligomers |
| PL1855841T3 (en) * | 2005-01-28 | 2010-05-31 | Saint Gobain Abrasives Inc | Abrasive articles and methods for making same |
| US7591865B2 (en) * | 2005-01-28 | 2009-09-22 | Saint-Gobain Abrasives, Inc. | Method of forming structured abrasive article |
| US8287611B2 (en) * | 2005-01-28 | 2012-10-16 | Saint-Gobain Abrasives, Inc. | Abrasive articles and methods for making same |
| US8435098B2 (en) * | 2006-01-27 | 2013-05-07 | Saint-Gobain Abrasives, Inc. | Abrasive article with cured backsize layer |
| US9358669B2 (en) * | 2012-06-29 | 2016-06-07 | Saint-Gobain Abrasives, Inc. | High adhesion resin-mineral systems |
Family Cites Families (18)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2668133A (en) * | 1953-04-13 | 1954-02-02 | United Shoe Machinery Corp | Adhesive bonding processes |
| BE569241A (en) * | 1957-07-08 | |||
| DE1956810A1 (en) * | 1969-11-12 | 1971-07-22 | Starcke Kg | Abrasives bound with photo-polymerisable resins |
| US4082634A (en) * | 1971-05-07 | 1978-04-04 | Ppg Industries, Inc. | Method of curing b-stage polyurethanes |
| US3806327A (en) * | 1971-06-14 | 1974-04-23 | Ashland Oil Inc | Coated abrasive grains encapsulated in a cross-linked thermoset polymmer |
| US4163647A (en) * | 1971-06-23 | 1979-08-07 | Norton Company | Method for producing coated abrasives |
| US4011063A (en) * | 1972-04-05 | 1977-03-08 | Minnesota Mining And Manufacturing Company | Low density abrasive utilizing isocyanurate resin |
| DE2247103B2 (en) * | 1972-09-26 | 1980-05-08 | Hoechst Ag, 6000 Frankfurt | Process for the manufacture of abrasives |
| US4047903A (en) * | 1972-09-26 | 1977-09-13 | Hoechst Aktiengesellschaft | Process for the production of abrasives |
| US4072592A (en) * | 1974-05-20 | 1978-02-07 | Mobil Oil Corporation | Radiation curable coating |
| US4129489A (en) * | 1976-02-14 | 1978-12-12 | Ppg Industries, Inc. | Preparation of polymer based powder coatings by ionizing radiation |
| US4107125A (en) * | 1976-07-01 | 1978-08-15 | E. I. Du Pont De Nemours And Company | Crosslinked aromatic polyimides and articles made therefrom |
| US4133909A (en) * | 1977-01-26 | 1979-01-09 | Mobil Oil Corporation | Radiation curable aqueous coatings |
| US4182790A (en) * | 1978-03-20 | 1980-01-08 | Thiokol Corporation | Liquid alkylacrylamides and related compositions |
| US4177310A (en) * | 1978-07-27 | 1979-12-04 | King Seeley Thermos Company | Method of metallizing paper |
| US4177314A (en) * | 1978-10-25 | 1979-12-04 | King Seeley Thermos Company | Method of printing paper |
| US4229274A (en) * | 1979-02-26 | 1980-10-21 | Ppg Industries, Inc. | Ultraviolet light curable compositions for producing coatings of low gloss |
| US4212899A (en) * | 1979-04-12 | 1980-07-15 | Union Carbide Corporation | Process for producing a colorant containing highlighted coated substrate |
-
1980
- 1980-10-08 US US06/195,030 patent/US4457766A/en not_active Expired - Lifetime
-
1981
- 1981-09-23 CA CA000386532A patent/CA1186276A/en not_active Expired
- 1981-10-07 JP JP56158894A patent/JPS5789565A/en active Pending
- 1981-10-07 FR FR8118880A patent/FR2491377A1/en active Pending
- 1981-10-07 DE DE19813139813 patent/DE3139813A1/en not_active Withdrawn
- 1981-10-08 GB GB8130409A patent/GB2087263B/en not_active Expired
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109963691A (en) * | 2016-11-16 | 2019-07-02 | 3M创新有限公司 | Structured abrasive article including the feature with improved structural intergrity |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2087263A (en) | 1982-05-26 |
| GB2087263B (en) | 1984-11-07 |
| FR2491377A1 (en) | 1982-04-09 |
| DE3139813A1 (en) | 1982-06-24 |
| US4457766A (en) | 1984-07-03 |
| JPS5789565A (en) | 1982-06-03 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CA1186276A (en) | Resin systems for high energy electron curable resin coated webs | |
| US4547204A (en) | Resin systems for high energy electron curable resin coated webs | |
| US4588419A (en) | Resin systems for high energy electron curable resin coated webs | |
| US4386943A (en) | Treated polyester fabric for use in flexible abrasives | |
| US3906684A (en) | Abrasive articles and their method of manufacture | |
| CA2171624C (en) | Abrasive articles comprising a make coat transferred by lamination | |
| TWI669192B (en) | Flexible grinding product with flattened surface and method for manufacturing the same | |
| US5378252A (en) | Abrasive articles | |
| AU621741B2 (en) | Patterned coated abrasive for fine surface finishing | |
| EP0855948B1 (en) | Abrasive article containing an inorganic metal orthophosphate | |
| JP3450593B2 (en) | Manufacturing method of abrasive products based on mesh | |
| KR100784658B1 (en) | Coated abrasive products and processes for forming same | |
| JP2008012670A (en) | Radiation curable abrasive-article with tie coat and method | |
| JP2000506452A5 (en) | ||
| US5549719A (en) | Coated abrasive having an overcoating of an epoxy resin coatable from water | |
| JP2002511497A (en) | Abrasive article and method having a coat | |
| US6120878A (en) | Abrasive articles comprising vinyl ether functional resins | |
| AU621878B2 (en) | Web with finishing coating useful as coated abrasive backing | |
| JP3954665B2 (en) | Method for producing decorative board using precoated paper | |
| EP1144515A1 (en) | Acrylated oligomer/thermoplastic polyamide presize coatings for abrasive article backings | |
| US9931731B2 (en) | Compressed polymer impregnated backing material abrasive articles incorporating same, and processes of making and using | |
| AU656640B2 (en) | Coated adrasive having a coating of an epoxy resin coatable from water | |
| JPH09239908A (en) | Precoated decorative paper |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |