CA2253577A1 - Antiloading components for abrasive articles - Google Patents

Abstract

An abrasive article, for example, a coated, bonded, or nonwoven abrasive article comprising a binder, a plurality of abrasive particles, and an antiloading component in a peripheral coating of the abrasive article.

Description

wo 97/42006 PCTIUSg7/04036 ANTILOADING COMPONENTS FOR ABRASIVE ARTICLES

BACKGROUND OF TEIE INVENTION

5 Field of the Invention The present invention relates to an abrasive article COm~JI;;-u~g a binder, abrasive grains, and pe.;?he.~l coating collly,ising an ~ntiloa~;~ col..ponenl.

Discussion of rpbt~p~ Art There are l,u,.. ero~ls types of abrasive articles. For exarnple, an ~b,~.l.~c article gcnelally co-l.t,l;ses abrasive particles bonded tog~pthpr as a bonded abrasive article, bonded to a ba~in~ as a coated abrasive article, or bonded into and/or onto a three~ mPn~ n~l nonwoven s~;.tlale as a nonwoven abrasive article. Each type of abrasive article may also be in a variety of forms. For example, a coated a~las~ve article can co-l"u-;3e a first layer (also known as a make coat), a plurality of abrasive pa~ Iicles adhered thereto and therein, and a second layer (also known as a sizecoat). In some ;~ ncçs~ a third layer (also known as a supersize coat) may be applied over the size coat. Alternatively, a coated abrasive article may be a lapping coated abrasive CCIll~ ;llg an abrasive coating (which also can be ref~ ,d to as an "abrasive layer") bonded to a backing where the abrasive coating CGIlllJl;SeS a plurality of abrasive particles di;."c.~ed in a binder. In nd~1ition a coated abrasive article may be a ~ u~;Lul t;d abrasive cclll~ .;ng a plurality of p~ ~cisely shaped abrasive composites bonded to a bac~in~ In this imt~n~ç~ the abrasive compositesco.... ..~ ;ce a plurality of abrasive palli~,les.
Abrasives articles are used to abrade a wide variety of substrates or wc,k~ ~es made from, for e-A ~ , wood, plastic, fiberglass, or soft metal alloys, or having a layer of enamel or paint. Typically, there is some degree of space b~cell these abrasive p~ li.,lcs. During the abrading process, material abraded from the substrate or w~,k~,;ece, also known as swarf, tends to fill the spaces b~l~een abrasive particles. The filling of spaces between abrasive particles with swarf and the s~lbsequ~nt build-up of swarf is known as lo?~ np T ~ - ~in8 p~,3_a concern because the life of the abrasive article is reduced and the cut rate of the abrasive article decleases (thus, more force may be le4uh~d to abrade). In ad-litirm~
loading is an exponential problem; once swarf begins to fill in the spaces bel~. _en S abrasive particles, the initial swarf acts as a "seed" or "nucleus" for a~lition~
loading.
The abrasive industry has sought loading-re~;sl~ul1 materials to use in abrasive articles. F --~les of loading-re~;sL~ll materials which have been used include metal salts of fatty acids, urea-formaldehyde resins, waxes, mineral oils, 10 clos.e~ dsilanes,cros~ lp~cilicon~C~andfluoloche.nicals. ~l~Ç~ dmaterials have been zinc stearate and calcium stearate. One theory for the success of metal sl~ ates as an ~ntilc-~ing agent is that the metal stearate coating powders offthe coated abrasive surface during the ~b,_d",g process, which in turn causes the swarf to also powder off of the surface, thus red~cing the amount of loading.
Stearate co~ g.c for the p~ ention of loading have been utilized by the abrasives industry for several dec~es It has been co.n~ n to utilize a binder with the stearate to assist in applying and ~ .;n;.lg the coating on the abrasive surface.
Some minor impro~enle.~ts over the years have been made by ~ p. stearates with higher melting points, for example, calcium or lithium stearate and by 20 illCGl~Olalil~g additives to enhance ~ntilr-~ing pc.rul~ ce~ for ~ _ rl fluorocl..~ lc Specific ~ .t~ to solve the pl~' -m of loading include those taught in U.S. Patent Nos. 2,768,886 (Twombly); 2,893,854 (Rinker et al.); and 3,619,150 ~Rinker et al.). U.S. Patent No. 2,768,886 discloses an a~l~sive article with a 25 coating of small, solid particles con~ g eSsenti~lly of ~ ~aLeS or p~lmit~tesU.S. Patent No. 2,893,854 ~licrloses a coated abrasive article coated with a contin~ouc film of a resin having ~ ~.;r~ Il . ..ly d,~,e. ~ed small, solid pa, Licles of a water-incsl-lble metallic soap of a saturated fatty acid having from 16 to 18 carbon atoms. U.S. Patent No. 3,619,150 ~ O3es a coated abrasive article having a 30 nonlo?~i~ coating comprising a mixed resin colllpos;lioll of a ~ ,. ,.,osv~ g resin and either a th~.moplaslic or elA~IOr~ iC resin and a water-d;~ ible metallic soap, in particular, a metallic water-incoluble soap of a C 16 to C 18 Salul~led fatty acid, d;a~ ed throu~hout the resin cûm~ûsiLion.
U.S. Patent No. 4,609,380 (Barnett) .1;c~ los~c an abrasive wheel having a ~ 5 binder system c.. ~ a binder and a smear-reducing co............. p~il,le polymer and conve.llional lubricants includi~ metal stearate salts such as lithium stearate.U.S. Patent No. 4,784,671(E1bel) discloses a process for hl~lu~ing the ~;i..li,~g p~,.ru"~ ce of a porous ceramic or plastic bound grinding or honing body cGnl~l;;,u~g filling the pore spaces at least in part with at least one metal soap, 10 inrl~lrli~ salts and soaps ofthe fatty acids of lauric acid, ~ lic acid, pslmiti~-. acid, stearic acid, arachic acid, and behenic acid. A g.i"ding p~ .rullllance h~?lû~
rlic~.losed is reduction of clogged pores of the body to avoid r~ Idu~ and sheetmetal jacket fonnstinnc U.S. Patent No. 4,988,554 (Peterson et al.) rlicrloses a coated abrasive 15 artide having a backing having a layer of abrasive grains ove.~;Gat.d with a loading ,;sl~ll coating comp,i~ g a lithium salt of a fatty acid on one side and a ple.
sensitive adhesive on the other side of the bac~
U.S. Patent No. 4,396,403 (Ibrahim) ~;C~iloses a coated abrasive article, which does not need a supersize coat of metal stearates or any other m~teri~l, which 20 instead il~COI ~JolaLeS phOSI~h~-~ ;C acids, partial esters of such acids, amine salts of such acids and partial esters, and/or quat~l"aty A~ salts with at least onelong s~bstitlJ~nt group into amino resin or glue sizing adhesives during the m~mlf~ctllre of the coated abrasive article.
U.S. Patent No. 4,973,338 (Gaeta et al.) ~I C~Osfis a coated abrasive that has 25 been oversized with an ~ntilo~r~in~ amount of a qual~ y ammonium anti-static Comrolln~ CG~ l;;.illg from about 15 to 35 carbon atoms and having a molecul~r weight not less than about 300. Examples of the quale "a.y ammonium compounds include (3-lauramido-propyl)L,u,l~ o~ . methyl sulfate, stearamidopropyldill,clLyl-beta-l,~.l, o~y~ll,yla.~ù,,olliu,,u~il, ale, N,N-bis(2-1,yd,oAyell,yl)-N-(3"-dodecyloxy-2"-l,ydlo~y~lu~,yl)",ell,yl~-.. ..o.~;~lm methr s~llf~te WO 97t42006 PCT/US97/04036 and ~le~ ~-~idopropyl-dimethyl-beta-llydl oAyeLllyl-~ o~ t ~ydl oge~n phos~h~F, Typically, the qua~ oni ~.. compound is coated out of a solvent, typically an aqueous alcohol solvent system.
U.S. Patent No. 5,164,265 (Stubbs) dicclQses an abrasive article having, 5 either applied as a layer coated over existing layers of an abrasive article or iluol~olaled into the coating formulation which will form the outermost layer ofthe binder, a fiuorochemical co".?ou~.d selected from the group co~ of co...?ou..ds colllyli~ing a fluolhlah,d ~liph~tic group attached to a polar group or moiety and col..~ounds having a moler~ r weight of at least about 750 and 10 co~ a non-fluolh~ated polymeric backbone having a plurality of pe.lda"l fluorinated ~liph~tir, groups COlll~,lis~g the higher of(a) a l..;~ . ofthree C-F
bonds, or (b) in which 25% of the C-H bonds have been replaced by C-F bonds such that the fluolocl~ ..ir~l compounds comprises at least 15% by weight of ~uorine.
,~lth~l~h the abrasive industry has widely used metal stearates with a good degree of sllccec~ the industry is always looking for "..~n~ed ~ntiloa~ling colllpon~ , particularly to IF ~gll~. n product life. ~Ith.m~h there have been anumber of improvements I ecF nlly for bar~ines, bond sy;,t~,...s, and minerals of coated abrasives, cG..lp~able improvements in ~ntilQadine colll~onenls have not yet 20 been achieved. That is, the illdll~tly is still seeking a c~ )onF l1 which is easy to apply, is relatively il,e,.~,.la;~e, and can be utilized during abrading of a variety of workpieces inrl~ ne paint, wood, wood sealers, plastic, Lbe.~lass, cG,..~)o~;le material, and automotive body fillers and putties.

SUMMARY OF TIIE ~VENTION
In the present invention, an ~ntilor~i~ col,l~)ol. ~"~ for an abrasive article has been developed which meets the needs of the industry, i.e., the present "l.~ell~ion relates to an abrasive article construction cG~ in;~ an ~nsilQ~lin~ co~llpone.llwhich cignifir~ntly ~ es loading, is coat~bl~, and is relali~ely in. ~ e.

The present invention relates to an abrasive article co...~ g (a) a backing having a major surface; (b) a plurality of abrasive particles; (c) a binder which adheres the plurality of abrasive particles to the major surface of the backing; and (d) a pe.iph~,.al coating comprising an ~ntik-~i~ col..po~ L of any offormulas 15 and 2 or ..I.Alures thereof The present invention also relates to an abrasive article Col~ g (a) a backing having a major surface; (b) a plurality of abrasive pal l;~les~ (c) a make coat which adheres the plurality of abrasive particles to the major su&ce of the b~.rL ;l~g (d) a size coat o~,e,ldying the make coat and the plurality of abrasive pa, licles, and 10 (e)apc.iph~ lcoating CGI~ ng an~nti~ lin~co..lponenlofanyoffonmllsc 1 and 2 or ~-~lures thereof In another embodiment, the present invention relates to a bonded abrasive co...l,. ;.:~ (a) a plurality of abrasive particles; (b) a binder adhering the plurality of abrasive particles together; and (c) a pc.;ph~ l coating COIIIyli~ulg an ~ntiloarling 15 co.,lpone.ll of any of formulas 1 and 2 or mixtures thereo~
In yet another embo~im~nt the present invention relates to a no.lwo~
abrasive Colll~ g (a) an open, lofty nonwoven ;,~stl alt, (b) a plurality of abrasive particles; (c) a binder adl.e.i.~g the plurality of abrasive particles into and/or onto the open, lofty nonwoven substrate; and (d) a p1.;ph~,ral coating co."~"i;,u~g an 20 antiloading co-upollenl of any of formulas 1 and 2 or mibctures thereof The present invention also relates to a method of making an abrasive article co .~ (a) providing a b~r~in~ having at least one major surface; (b) appljin~, amake coat binder precursor over the at least one major surface of the b~c~ , (c)rmhedding a plurality of abrasive pa, L;CIeS into and/or onto the make coat binder 25 p~ u~or, (d) at least partially curing the make coat binder precursor to form a make coat; (e) applying a size coat binder precursor over the make coat and the plurality of abrasive particles; (f) curing the size coat binder pre~iu,~or to form a size coat; (g) applying a pe~;"he. 7~1 composition over at least a portion of the size coat, said cG.Ilpos;Lion Colll~ lg an ~ntil9, ~ling co-llpone.,l of any of form~ 1 and 2 30 or ~uAlurcs thereof; and (h) drying the composition to forrn a pc.i,uh~ coating.

The antiloading coll,pone.,L can be any offormulas 1 and 2 or ~ UI~,S
thereof:

w~(x)p ~i2 R

~ rG111 Rl and R2 are independ~ tly OH or OR, R is an alkyl group;
X is 0, S, NEI, or a divalent ~lirh~tic or aromatic linking group having 20 atoms or less and col-lA;..:~e carbon and, optionally, nitrogen, oxygen, phGs~h~lus, 10 and/or sulfur in the ~1irh -~ic or aromatic group or as a sl~hstitu~nt to the ~lirh~tic or aromatic group;
pisOor l;and W is an alkyl group, or W is a fluo. 1.. 1ed hydrocarbon having a formula C",H,F2~,l+~, where a is O to 2m and m is 4 to 50, ~1,~ the alkyl group or the 15 fluorinated hydrocarbon may contain oxygen atoms in a backbone of the alkyl group or the fluorinated hydrocarbon, .t;~l,e~ ely, in an amount ranging from 1 to 1/2 a total number of carbon atoms present in the allcyl group or the hydrocarbon, respectively;

1(3 3 (AS~R4 2 whelein R3 and R4 in~epPn~çntly are H or an alkyl group;
Z~ is a monovalent anion;
A is a divalent ~liph~tic or aromatic linking group having 20 atoms or less and con~ g carbon and, optionally, nitrogen, oxygen, ph~.~ho~"s, and/or sulfur in the ~liph~tic or aromatic group or as a substih~-nt to the ~lirh~tic or aromatic VOSSIUS & PARTNER
PCT/US97/04036 23 J '' r~TENTA~iiLTE
MINNESOTA MINING AND MANUFACTURING CO. ~ ;8 S~ L~ r ~ 4 Our Re f .: B 2 9 2 8 PCT . 675 hU.~ E~I
group, with the proviso that the linking group is connected by a carbon atom to N
of formula 2;
tis0or l;and W is an alkyl group, or W is a fluorinated hydrocarbon having a formula S C,l,H.F2"~l., where a is 0 to 2m and m is 4 to 50, wherein the alkyl group or the fluorinated hydrocarbon may contain oxygen atoms in a backbone of the alkyl group or the fluorinated hydrocarbon, re5pee~i~ely, in an amount ranging from 1 to 1/2 a total number of carbon atoms present in the alkyl group or the hydrocarbon, rest,e~,~ively.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a cross-section of an embodiment of a coated abrasive article in accordance with the present invention.
Figure 2 is a cross-section of an embodiment of a structured abrasive article 15 in accordance with the present invention.
Figure 3 is a partial expanded view of a nonwoven abrasive article in accordance with the present invention.
Figure 4 is a cross-section taken along line,~-~ofFigure 3.
Figure 5 is a reduced plan view of a portion of a col-c~ten~te of abrasive 20 discs in accordance with the present invention.
Figure 6 is a greatly reduced perspective view of a roll of coated abrasive material in accordance with the present invention.
Figure 7 is a cross-section of another embodiment of a coated abrasive article in accordance with the present invention.
DETA~ED DESCRIPTION OF THE INVENTION
Abrasive articles and methods of making and using abrasive articles in accordance with the present invention will be discussed in more detail below.

~7~ ~I,EI~t~ t ï

Abrasive Artides Abrasive articles typically col"~"ise a plurality of abrasive p~licles adhered by a bond system cGInlJlising a binder which can be derived from a binder ,u,~or. F--- -. Ie~ of abrasive articles include coated abrasive articles such as 5 lapping or structured abrasive articles, bonded abrasive articles, and nonwoven abrasive articles.
Abrasive articles generally co"""ise abrasive p&Licles secured within a binder. In a bonded abrasive, the binder bonds the abrasive particles to~eth~r in a shaped mass. Typically, this shaped mass is in the form of a wheel and thus it is 10 coll"llonly r~f~.led to as a grinding wheel. In fiGIlwO~,en abrasives, the binder bonds the abrasive particles into and/or onto a lofh,r, open7 fibrous substrate. In coated 5~1aSiVt;S, the binder bonds the ~b~ , particles to a ;~ llaLe or b?lc~in~:
Abrasive artides of the present invention co...l., ;se an qntiloa~ling coll-l)o~ in a ~,.;"he,7l1 coating of the abrasive article capable of contqr~ting a 15 workl).ece. The term "pc.;i)he,~l coating'7 as used herein refers to the ouLt;llllos coating of an ?bl~S;~e article which cont~At~ a wulkl lece to be abraded.

Coated Abrasive Articles Coated abrasive articles of the invention may be produced with coatable 20 binder precursor col"l)osilions, desc,;l,ed herein, on a b~ ~~i~ As l .~ n;oned above, there are a variety of types of coated abrasive articles.
A backing for a coated abrasive article of the present invention c. n be any number of various materials conv~ntion~'ly used as backings in the mqnllfiqctl~re of coated abrasives, such as paper, cloth, film, pol~ ,.ic foam, vl~lrqni7~d fibre,25 woven and nonwoven materials, and the like, or a colllbh~aLiGn of two or more of these mqteriql~ or treated versions thereof. The choice of backing material willdepend on the inten~ed application of the abrasive article. The ~Ir~ g~ll of thebacking should be sl~ffirient to resist tearing or other damage in use, and the th~ ness and smoothness of the backing should aUow acl~ e...c.lL of the product 30 thickness and smoothness desired for the int~nrled applirqtiAn : . .. .

The backing may also be a fibrous re-l~rced thermoplastic, for example, as dic~ sed in U.S. Patent No. 5,417,726 (Stout), or an endless spl;cP1ec~ belt, for example, as ~licrlosed in WO 93/12911 (Benedict et al.). Likewise, the backing may be a polymeric substrate having hooking stems p~u;e;t~ l.el~Lo-,-, for example, ~ 5 as di~closed in WO 95/19242 (Chesley et al.). Similarly, the backing may be a loop fabric, for e .- l e, as described in WO 95/11111 (Follett et al.).
The backing may be smooth, te,.lured, or pc.ro~aled and may have a th;-l~n~cc ranging generally from about 25 to about 10,000 .lùc-~r..~ , typically from 25 to 1000 micrometers.
The backing may co.. l,.ise a polymeric film, cloth, paper sheet, treated versions thereof, a screen made from plastic or metal, and treated or U.lt. caled cornhin-q-tiQns thereo~ In some appli~-q-tionc it is also p. ~ ft;. ~ble that the backing be .le.~,. oof. The thickness of the backing should be sllffi~ient to provide the ~l.englh desired for the int~n-ied applir~;on nevertheless, it should not be so thick 15 as to affect the desired flc~.ibiLly in the coated abrasive product. The film backing may be made from a ll.~ ,l..opla~ic material such as polyamides (nylon), polyester, poly~ lene, polyethylene, pol~.lrc~ e, cG.~.h~ ;onc thereof, and the like. The film backing may also be a microvoided film bq.~ I~ing As used herein "microvoided" means that the film has intemal polosily. A particularly p.~rti"~.d 20 film is a microvoided polyester (plef~ably polyethylene teleF.l.l~.~lqte) film having a th~ nesc ranging from 0.01 mm to 0.25 mm, more preferably 0.05 mm. An example of a microvoided polyester film is one which is co..u..~ rc;ally available from ICI T .imite~l United King~om under the trade ~P ~ l ;on "475/200 MELINEX
MV". The film backings may be primed or uil~l..llc~. The backing may also be a 25 laminate of p~c./~L", two polymeric fiLms, paper/cloth/fiLrn, film/no,.v~o~cn material, and the like.
With ~tiÇe.~nte to Figure 1, a coated abrasive article 10 of the present invention may include a first coating layer 12 (co~ ..only referred to as a makecoat) bonded to one side (a major surface) of a backing 11, at least one layer of abrasive particles 13 bonded to the backing 11 by the make coat 12, a second coating layer 16 (cG~ only referred to as a size coat) ove.la~rillg the a~
particles, and a peripheral coating 14, COlllpli~ g an ~ntilo~lin~ c~...ron~ ofthe present invention, over at least a portion ofthe second coating layer 16.
Coated abrasives of the present invention also include lapping abrasive 5 articles and structured coated abrasive articles. A lapping coated abrasive article Co~ )lise,s a backing having an abrasive coating bonded to the backing; the abrasive coating COIllyliSillg a plurality of abrasive particles distributed in â binder. In some ;"C~ncec the binder bonds this abrasive coating to the b. ~l~in~ Alternatively, an ition~l material may be used to bond the abrasive coating to the b~ in~, which 10 may be selected for eY~ nple, from the binder pr~ .,ul~Ol~ desc~il,ed herein and may be the same or dilT~,renl than the binder precursor used to form the abrasive coating.
G~n~,.dJly, the particle size of the abrasive particles used in a }apping coatedabrasive ranges, on average, from about 0.1 to less than about 200 miclonlet~
typically, 0.1 to 120 mi~"o"l~,te.~. The abrasive coating may have a smooth outer 15 surface or a textured outer surface. The abrasive coating may also further co,..~ e additives as dicc~ssed herein.
With r~rerence to Figure 2, a structured abrasive article 20 com~ ses a backing 32 having a plurality of pl~.isely shaped abrasive c~ml)osXes 31 bonded to a major surface 33 ofthe b. ~L ;.~, 32 and a pe-;phe.~l coating 38, co.~ 8 an20 ~ntilo~ n~ colllpoll. .lt of the present invention, over at least a portion of the plurality of abrasive composites 31. These abrasive CGnlpGS;IeS comprise a plurality of abrasive particles 34 di~L~ilnlled in a binder 35. In some ;f.~h ~ce~, the binder 35 bonds the abrasive co~ )osiles to the b;~in~ Altematively, an additional m~teri~l may be used to bond the abrasive co"l~fj.,;le to the ba-lring which may be selecte~
25 for example, from the binder pl~ GI~ des~,libed herein and may be the same ordi~ nl than the binder plt;cul jor used to form the abrasive col..l.oc;le Generally, the particle size range for abrasive particles used in a structured coated abrasive is the same as that used for a coated abrasive article colll~ g a make coat and size coat as des.,l;bed herein. The abrasive CO...l~GS;lf.S may also 30 colll~,l;se additives that are di~cllssed herein.

CA 022~3~77 1998-11-0~

As des."il~ed herein, each of the embo-lim~nts of a coated abrasive article cont~in.c a peripheral coating over at least a portion of the binder and abrasive particles of the abrasive article. For exarnple, the peripheral coating may overlay a size coat, an abrasive coating, or abrasive composites This coating may be r~Çelle~
5 to as a "supersize coat" for coated abrasive articles having make and size coats.
In some instances, it may be p-efe~ed to incorporate a pressure sensitive adhesive onto the back side of the coated abrasive such that the res -ltin~ coated abrasive can be secured to a back up pad. Represenh~ e exarnples of pressure sensitive adhesives suitable for this invention include latex crepe, rosin, acrylic 10 polymers and copolyrners e.g., polybutylacrylate, polyacrylate ester, vinyl ethers, e.g., polyvinyl n-butyl ether, alkyd adhesives, rubber adhesives, e.g., natural rubber, synthetic rubber, chlorinated rubber, and mixtures thereo~ A plcre,~ed pressure sensitive adhesive is an isooctylacrylate:acrylic acid copolymer.
Alternatively, the coated abrasive may contain a hook and loop type 15 ~tt~chment system to secure the coated abrasive to the back up pad. The loop fabric may be on the back side of the coated abrasive ~vith hooks on the back uppad. Alternatively, the hooks may be on the back side of the coated abrasive ~,vith the loops on the back up pad. With reference to Figure 7, the coated abrasive 70may include a first coating layer 12 bonded to a major surface of the backing 11, at 20 least one layer of abrasive particles 13 bonded to the backing 11 by the first coating layer 12, and a second coating layer 16 overlaying the abrasive particles, a third coating layer 14 (also referred to as a peripheral coating), comprising an antiloading component of the present invention, over at least a portion of the second coating layer 16, and hooks 1~ attached to the backing 11 on the back side, i.e., the side 25 opposite to the major surface of the backing 11 bearing abrasive particles 13.
This hook and loop type ~tt~chm~ent system is further described in U.S.
Patent Nos. 4,609,581 and 5,254,194~95/19242 ¦dnd US~N's 08/181,19:~, r-~ ~b8/181,193; ~,.d 0~/181,1~. For example, a make coat precurosr may be coated directly onto a loop fabric, which may be a chenille stitched loop, a stitchbonded loop (for example, as dislcosed in U.S. Patent No. 4,609,581 (Ott), or a brushed L ~ . ~. Pa~ 0 ~/ ~4 ~ ( C/~ CJ~C~ ) . a .~, . s fJo~ 0~ 34~ ~ /'3q~-7 ~( J ~
-11- i'. ! ~. , S,;-"~ [--loop, for c r le~ brushed nylon. The loop fabric may also contain a sealing coatto seal the loop fabric and prevent the make coat pr~iu,~or from pC ~llaling into the loop fabric. Alternatively, the make coat precursor may be coated directly onto the loop fabric, for f~Y ~mrle~ as ~ rlosed in W0 95/11111 (Follett et al.). In this 5 all;~r~gP~f ~1l, the loop fabric can releasably engage with hooking stems present on a support pad. The make coat p. ~,u, ~or may also be coated directly on a hooking stem substrate, which generally COIIIIJl;Sf S a substrate having a front and back surface. The make coat precursor can then be applied to the front surface of thesubstrate, the hooking stems protruding from the back surface. In this &lI;~ , 10 the hooking stems can releasably engage with a loop fabric present on a support pad.
It is also within the scope of this invention to have a binder and plurality of abrasive particles adhered directly to a loop fabric and have the antiloading component present in a pe.i~,kel~l co~ti~
The coated abrasive can be in the form of a roll of abrasive discs, as desc, ;hed in U.S. Patent No. 3,849,949 (Stf inh ~er et al.).
The coated abrasive may be converted into a variety of di~e e ..l shapes and forms such as belts, discs, sheets, tapes, daisies and the like. The belts may contain a splice or a 30int, alternqtively the belts may be sl licel~ ss such as that taught by in W0 93/12911. The belt width may range from about 0.5 cm to 250 cm, typically whcre from about 1 cm to 150 cm. The belt length may range from about S cm to 1000 cm, typically 10 cm to 500 cm. The belt may have straight or scalloped edges. The discs may contain a center hole or have no center hole. The discs mayhave the following shapes: round, oval, oct~on pent~n, h~Yagon or the lilce; allof these converted forms are well known in the art. The discs may also contain dust holes, typically for use with a tool Co~ a vacuum source. The ~ mp~ter of the disc may range from about 0.1 cm to lS00 cm, typically from 1 cm to 100 cm. The sheets may be square, tri~n~ r, or rec~ r. The width ranges from about 0.01 cm to 100 cm, typically 0.1 cm to 50 cm. The length ranges from about 1 cm to 1000 cm, typically 10 cm to 100 cm.

For ~ - ~'e, Figure 5 shows a plan view (reduced) of an a~.~;.,~ article of the invention, a conr~t~nDtiQn 50 of edge-co~ ed coated abrasive discs 72 capable of being convolutely wound to form a roll which can be easily unrolled.
Al~ ately, other shapes of coated abrasive can be used. A cor.c~ten~;ol- of coated abrasive is more fully desc-il.ed in ~ -c~'s U.S. Pat. No. 3,849,949. Each disc 72 preferably has a structure as shown in cross-section, for exarnple, in Figure 1 and is joined to at ieast one other shll;l&ly constructed disc 72 along a straight edge 74 of the disc formed by removal of a small se.~... -.~ defined by a chord having a length less than 1/2 the radius of the disc. Straight edge 74 is preferably pclror~led for 10 easy separation ofthe discs along the chord; however, ptlrolalion is not n~Ges~ y.
This concqt~n~tion 50 of coated abrasive discs, when wound into a roll, has a pc-iyhel al coating (for ~Yqmple, as shown in Figure 1), C~ \B an ~ntilo~q~ ng c~ po~ of the present invention, of one disc 72 in direct, re~ b'e contact with the PSA on the back side of another disc 72 when the con~?tenation is convolutely 15 wound. The discs can be easily separated from one another when desired.
Alternatively, with le~. ellce to Figure 6, which shows a reduced pt.~e~ /e view of another pl~rel-~d article of the invention, a p. c~gecl roll 60 of coated abrasive employing an antiloading cGl..ponent of the present invention may be used. Roll 60 comprises an elongated sheet of coated abrasive mDtPriql 82 of the 20 type shown in cross-section in, for c , ~, Figure 1. The materials of construction suitable for roll 60 can be the same as those used in afore ..~n~ jol ed coated abrasive article 10. In Figure 6, it can be seen that when the coated abrasive material is wound into a roll, a peli?h~.~l coating 81 ctjlllpl;~i,lg an qntiiQ, ~i~
cGmpone.ll ofthe present invention will be in direct, releq.~qb'e contact with a layer 25 of PSA 83 . When the user desires to remove a piece of coated abrasive m~t~o.ri~
from roll 60, the user merely unwinds a portion of roll 60 and cuts or tears this portion from the roll.
When a PSA is used, if necess--y to prevent transfer ofthe ~ntiloa~
cGl.,pon~,.ll to the PSA or vice versa, a release liner may be used, the roll may be wound loosely, or a binder (in ~-nr~lnts as des~.lil.ed herein) may be i,.co,~olaled along with the antiloading co~,ponenL.
It is also feasible to adhere the abrasive particles to both a major or wu,ki"g surface and the opposite surface of a bnc~ing The abrasive pal li.,les can be the 5 same or .li~l e.,l from one another. In this aspect, the abrasive article is ~c.centi~lly two sided; one side can contain a plurality of abrasive particles which are di~èr~.,lL
from a plurality of abrasive particles on the other side. Allellla~ y~ one side can contain a plurality of abrasive particles having a di~ .d particle size than those on the other side. In some inct~rlc~c~ this two sided abrasive article can be used in a 10 manner in which both sides of the abrasive article abrade at the same time. For e .- ' , in a small area such as a corner, one side of the abrasive article can abrade the top ~olk~,:ece surface, while the other side can abrade the bottom workpiecesurface.

Nonwoven Abrasive Artides Nonwoven abrasive articles are also within the scope of the invention and include an open, lofty fibrous s.lbsL~ale having a binder which binds fibers at points where they cont~-t Optionally, abrasive particles or nonabrasive particles (such as fillers) may be adhered to the fibers by the binder if the m~mlf~eh~rer desires. For 20 e~ ,lr with, erer -,ce to Figure 3, a nonwoven abrasive COIll~ .e,S an open lofty fibrous substrate coll-plislng fibers 50 with nodules 51 thereon; the nodules colnpl;s.llg binder 54, which binds a plurality of abrasive particles 52 to the fibers, and p."iphel~l coating 56, COlllplli..llg an antiloading coll.~,onenl ofthe present invention, coated over at least a pûrtion of binder 54 and a~lasi~e particles 52.
Figure 4 illustrates a cross-section of nodule 51 showing peliph~,~l coating 56,COIllpl;~lng an ~ntiloarling coll.ponc,l~ ofthe present invention, present over at least a portion of the binder 54 and abrasive particles 52.
Nonwoven ab,a;,;~.,s are described generally in U.S. Pat. Nos. 2,958,593 (Hoover et al.) and 4,991,362. In the present invention, an ~ o~ g cor.,pon~nl is present in a peripheral coating over at least a portion of the binder.

Bonded Abrasive Articles Bonded abrasive articles are also within the scope of the invention. A
bonded abrasive article co~ uliSeS a binder which adheres abrasive pal licles together 5 in the form of a molded product. Bonded abrasives are desv,il,ed generally in U.S.
Patent No. 4,800,685 (Haynes). In the present invention, an ~nti~c- ~ing CGlll~Ol~.ll is present in a p~,iph~ l coating over at least a portion of the binder.

Methods of Making Abrasive Articles Coated ~b.. ~ A~ticles Coated abrasive articles of the present invention may be pl~ared using coa~ binder precursors. These binder precursors may be used ;~depe~d~ntly, to form a ll~a~m~ll coating for the bac~ing, for; , 'e, a back coating (;ba~~.ci7e coat), front coating (presi7e coat), or saturant coqting; a make coat to which 15 abrasive particles are initially anchored; a size coat for t~n~io~sly holding ab,as;~, particles to the b a-L-ing or any co,lll,inalion of the a~or~ ;onPd coatings. InititlnJ a binder precursor can be used in coated abrasive article embo~ ntc where only a single coating binder is employed, i.e., where a single coating takes the place of a make coat/size coat combination, for eY~rnple~ in a lapping coated 20 abrasive.
When a coatable binder plevll,~or desçribed herein is applied to a bac~ing in one or more lle~t~ steps to form a tl~ P--~ coqtir~ the ~ F~1 coating can be cured, e.g., th~,~l,.ally by passing the treated backing over a heated drum; there is no need to festoon cure the backing in order to set the l~ 1 coating or 25 co~ g.c Ref~v,vnce to pre~ ing a coated abrasive article having a make and size coat is set forth. After the backing has been propelly treated with a llv~ coating, if desired, a make coat binder precursor can be applied. A~er the make coat binder pl evUI :!iOr iS applied, abrasive particles can be applied into and over the make coat 30 binder precursor. The abrasive particles can be drop coated or electrostatically coated. Next, the make coat binder precursor, now bearing abrasive particles, can be exposed to a source which generally so';~ifiPs or sets the binder suffir;~ntly to hold the abrasive particles to the bqc~i~ e.g., a heat source. In some i~ cP$~
the make coat binder prt-,ul ~or can be pal l;ally cured before the abrasive pa, li.,les are embedded into the make coat as des~l;l,ed in U.S. Patent No. 5,368,618 (Masmar et al.). Then, a size coat binder ~ ;ul~or can be applied. The make coatbinder precursor and/or size coat binder precu.~or can be applied by any suitable method inr.hlrli~ roll coatin~ ~IJlajillg, die co~q~tin~ curtain coating, and the like.
The t~nlp~ ule of the make coat binder precursor and/or size coat binder precursor can be room tc.llpel~lule or higher, preferably from 30 to 60~C, more preferably from 30 and 50~C. The size coat binder ~re~,ul~ol/a~l~s;./e particle/(at least partially cured) make coat c~ ;on can be exposed to a heat source, for PYqlnple, via a festoon or drum cure, or, ~Isernqtively, a radiation source. This process will s~b~ 11y cure or set the make and size coat binder precursor used in the coated abrasive constructions. Standard thermal cure con~1itions can be used to effect curing, for ~ ,le, tenll)el~tules bet~ n 50 to 150~C, typically 75 to 120~C, preferably 80 to 115~C.
It is also feasible to use a hot melt binder precursor, for ~ ~;....ple as disclosed in WO 95/11111, to form a coated abrasive article. The hot melt make 20 coat binder precursor can be p~~ d by mixing the componenls of the hot melt resin in a suitable vessel, preferably one that is not ~ to actinic ru~iqtil~n~
at an elevated tt.llpc-al-lre sllffi~;ent to liquify the materials so that they may be effiriently mixed but without thermally degrading them (e.g., a te.llpc,~l~re of about 120~C) with stirring until the Coll~Jone.ll(s) are thoroughly melt blended. The 25 colll~on~lts may be added .~imull~ ~eo,~ly or seq~l~nti~lly. One p~f. .l~;d hot melt binder plecu-~or co---l,-;ses an epoxy-co,.~ ;..g mqt~ri~l a polyester conll)on~having hydroxyl-co~ end groups, and an initiator, preferably a photoinitiator, for e~qmrlç, as disclosed in U.S. Patent No. 5,436,063 (Follett et al.).
It is also possible to provide the hot melt make coats as ullcllled, 30 unsuppolled rolls of tacky, pres~ule sensitive adhesive film. Such films are useful in CA 022~3~77 1998-11-0~

the make coat to an abrasive article b~c~in~ It is desirable to roll the tacky film up with a release liner (for example, silicone-coated Kraft paper), with subsequent paC~ n~ in a bag or other container that is not lldnspare"l to actinic radiation.
The- hot melt make coats may be applied to the abrasive article backing by extruding, gravure printing, or coating, (e.g., by using a coating die, a heated knife blade coater, a roll coater, a curtain coater, or a reverse roll coater),. When applying by any of these methods, it is prefe~ led that the make coat be applied at a temperature of about 100~ to 125~ C, more preferably from about 80~ to 125~C.
Coating is a desirable application method for use with J weight cloth bac~in~c and other fabric bacl~ingc of similar porosity.
The hot melt make coats can be supplied as free st~n~ing, unsupported pressure sensitive adhesive films that can be l~min~ted to the backing and, if necessary, die cut to a predefined shape before l~min~tion. T ~min~tion temperatures and pressures are selected so as to minimize degradation of the backing and bleed through of the make coat and may range from room tempe. ~LIlre ~2 0't ~ Po. ~ 2 4 ~ P~
~< to about 120~C and about(~30 to 250 psi,l A typical profile is to l~min~te at room r G ~q Sk~ ~
X temperature and 00 psi~ Lamination is a particularly p.erell~d application method for use with highly porous bacl~ing~, for example, as described in WO 95/11111.
Preferably, the hot melt make coat is applied to the abrasive article bac~ing by any of the methods described herein, and once so applied is exposed to an energy source to initiate the curing of the epoxy-containing material. The epoxy-cont~ ng material is believed to cure or crosslink with itsel~
In an alternative rn~nllf~ctllring approach, the make coat is applied to the backing and the abrasive particles are then projected into the make coat followed by exposure of the make coat to an energy source.
A size coat may be subsequently applied over the abrasive particles and the make coat as a flowable liquid by a variety of techniques such as roll coating, spray coating or curtain coating and can be subsequently cured by drying, he~ting, or with .

WO 97/42006 PCT/USg7104036 cle~ll oi1 bearn or ultraviolet light r~ tion The particular curing appr. ~ t may vaTy dep~n-iing on the ch~ ..y ofthe size coat.
A structured coated abrasive may be ple?a.cd as des~lil)ed in ~ çcs' U.S. Patent Nos. 5,152,917 (Pieper et al) and 5,435,816 (spulgeon et al.). One 5 method involves 1) introducing the abrasive slurry onto a production tool, vvLe~
the prodllction tool has a ~peçifi~d pattern; 2) introdl~cir~ a backing to the outer surface of the production tool such that the slurry wets one major surface of the backing to forrn an interme~ te article; 3) at least partially curing or gelling the resinous adhesive before the h~lell~lediate article departs from the outer surface of 10 the production tool to form a structured coated abrasive article; and 4) removing the coated abrasive article from the production tool. Another method involves 1)introducing the abrasive slurry onto the ba cl~ing such that the slurry wets the front side of the backing forming an i~ltel ~..çA; l e article; 2) introducing the intellllediale article to a prod~lction tool having a ~pe~ ;r~ed pattern; 3) at least partially curing or 15 gelling the l~i;nous adhesive before the inte~...e l;~e article departs from the outer surface of the production tool to form a structured coated abrasive article; and 4) removing the structured coated abrasive article from the production tool. If theprocluctiQn tool is made from a t,~ 51J~enl lllatel;al, e.g., a poly~,rol,ylene or polyethylene Illelllloplastic, then either visible or ultraviolet light can be ~ ed 20 through the production tool and into the abrasive slurry to cure the le~.nOUSadhesive. Alternatively, if the coated abrasive backing is ~ .,nl to visible or ultraviolet light, visible or ultraviolet light can be tl~ ed through the coatedabrasive ba~ing In these two mçtho-l~ ' the resulting so':~ifiçd abrasive slurry or abrasive col"i)o~i~e will have the inverse pattem of the production tool. By at least 25 partially curing or solidif ving on the production tool, the abrasive co..",osiLe has a precise and predete-l-~,cd pattern. The l~ OuS adhesive can be further soli~lifiPd or cured off the prod~lcfiQrl tool.
A lapping coated abrasive can be pl . p&. ~d by coating an abrasive slurry onto at least one side of a bacl~ine A pl ~;~. l ed ba~l~ing is a polymeric film, such as 30 polyester film that contains a primer. Coating can be accc rt ~ by spraying, rotogravure coating, roll coati-~ dip coating or knife coating. After the coating process, the slurry can be solidified, to form an abrasive coating by cA~.Gs.lrc to an energy source inr,l~lri;ng thermal and radiation energy (e.g., ele~l on beam~
ultraviolet light and visible light).
- 5 In all coated ab~ c article embo~imentc ofthe present invention, a p~.;phe,~l comrocitirJn~ which co~ ,.;ses an Qntilr~Q~ CG~IlpOl CU~, iS applied over at least a portion of the binder of the coated abrasive article so that the Qnti'oa~
co,-,poncnl is capable of contacting a workpiece. The method of making a pcl;~,he.~l comrosition and ~Ulllllllg a peripheral coating is des~,lil,cd herein.
Nonwoven Abrasive Articles A nonwoven abrasive article may be prcp~ ed by colnhining a binder pre~,ul ~or with abrasive particles and optional additives to form a coatable, binder precul~or slurry. The slurry can be coated, for example, by roll coating or spray coating, onto at least a portion ofthe fibers of a lofty, open, fibrous web, and the resulting structure s~ to conriitirJnc s~lffir;~nt to affect curing of the binder ple~;ul~or~ as descl;l,ed herein.
A general pl~ cedure for making lofty, open no.l~voven ablas;ics in~ les those generally illu~llalcd in U.S. Pat. No. 2,958,593, and those pl~,l,arcd accol-lil,g to the tcachi~s of U.S. Pat. No. 4,991,362 and U.S. Pat. No. 5,025,596.
A pcl;~h~.~l cc,lllpos;lion CCi~ g an ~ntilor~ing cc. ~.l.oru -l is applied over at least a portion of the cured slurry to form a pel ;yhe~l coating so that the antilo~ ~ colllponelll ofthe ptl;"hc,al coating is capable of contacting a workpiece. The method of making a p~ ~;yh~ ~1 colll?osition and lo. l..;~.g a 25 p~,;?h~,~l coating is desc.;bed herein.

Bonded Abrasive Artides A general procedure for making a bonded abrasive of the invention inr;1udes mixing togethe~ binder precursor, abrasive pal l;cles, and optional additives to fonn 30 a homogenous rnixture. This mixture is then molded to the desired shape and ~;...Pn- ons. The binder pr~.;ul~or is then subjected to col~d;liQl~c des~i,il,ed herein, s~lffiri~nt to affect curing and/or solidifi~stion to form a bonded abrasive.
A ptli~hc,~l composition co...~ an sntil~s,r~in~ co"")on.,.ll is applied over at least a portion of the molded product to forrn a p~,. ;ph~ l coating so that 5 the snti~Q,s,tlin~ component of the coating is capable of cont~ing a wollc~ ie c e The method of making a peli~,h~ I co,l",Gs;lion and rc,lll"n~, a p~..iph21~1 coating is des~,lil,ed herein.

Binder System A binder in accordance with the present invention COIll~ eS a cured or solidified binder precursor and serves to adhere a plurality of abrasive particles together (as in a bonded abrasive article) or to a ~ul~ lale (i.e., a backing for a coated abrasive or a nonwoven for a nonwoven abrasive).
The term "binder precursor" as used herein refers to an u~.ured or a 15 fiowable binder.
Organic binders suitable for an abrasive article of the present invention are forrned from an organic binder plt;~;UI:~Ol, it is, however, within the scope of the present invention to use a water-soluble binder pl~ or or water-di~el ~;ble binder precursor, such as hide glue. The binder precursor is preferably a 20 the.--~os~ resin. F~ lesoftl;eose~ resinsinclude ph~nf-lic resins, ~llmoplâsl resins having pendant a,~3-unsaturated ca l,on~l groups, ur~Lâlle resins, epoxy resins, urea-formaldehyde resins, isocy~l~lrate resins, .uP~ e-formsld~hyde resins, acrylate resins, acrylated iso(,ya~ e resins, acrylated ulel~ e resins, a-,lylated epoxy resins, bi~msl~imi~le resins, and mixtures thereo~
Phenolic resins are coll".,only used as an abl~s;~, article binder ple~,ul~or because of their thermal propt;l lies, availability, cost and ease of hsn~lli~ There are two types of phenolic resins, resole and novolac. Resole ph~n- lic resins have a molar ratio of formaldehyde to phenol, of greater than or equal to one to one, typically between 1.5:1.0 to 3.0:1Ø Novolac resins have a molar ratio of formaldehyde to phenol, of less than one to one. The ph~nolic resin is plt;~lably a WO 97/42006 PCTtUS97/04036 resole phP,nolic resin. F~ .ples of col,u.l~,.c;ally available ~h o!ic resins include those known under the trade d~;g~ ;on~ "Varcum" and "Durez" from Occid~
Chemical Corp., Tona~da, NY; "Arofene" and "Arotap" from Ashland Chemical Company, Co!~mh~L~ OH; "Resinox" from Monsanto, St. Louis, MO; and "R~k~lite" from Union Carbide, Danbury, CT.
It is also within the scope of the present invention to modify the physical plOp~,. Lies of a phPnolic resin. For example, a p~ er, latex resin, or reactivediluent may be added to a phenolic resin to modify flc~ ;ly and/or ha,.lll.,ss ofthe cured phenolir, binder.
- 10 A pl~f~"le~ ~lunoplast resin is one having at least one pendant a,~-ul~salulaled c~l,o"yl groups per mn'e~l~le, which can be p,.,p~ed accol.li,lg to the dicrl~s~re of U.S. Patent No. 4,903,440 (Larson et al.).
Aminoplast resins have at least one p~ndalll x,B-unsalu,~.ted c~ bollyl group per -le.,ule or oligolll.,n These unaalulaled carbonyl groups can be acrylate, ' - ,rylate or acrylamide type groups. F - ~ 'es of such materials include N-LydloAylll~lhyl-acrylamide~ N,N'-o~ydinl~,lllylenebiQacrylamide, ortho and para acrylam Jom~thylated phenol, acrylamidolllelllylated ph~nnlir, novolac and co...l~ ql;c nL. thereo~ These materials are further des.,l;bed in US Patent Nos.
4,903,440; 5,05S,113; and 5,236,472.
Polyul~,Lhalles may be prepared by reLcL;ng near stoichiometric a llounL~ of polyisocyanates with polyfunctional polyols. The more CQ~ OII types of polyisocy~aLes are toluene diisocyanate (TDI) and 4,4'-diisocy~n~todiphpnylmeth~ne (MDI) which are available under the trade de7;e..~l;onL "Isonate" from Upjohn Polyll.cr Chemicals, K~l~m~7oo, MI and 25 "Mond~r" from Miles, Inc., Pill~bul~ll, PA. Common polyols for flexible polyul~ es are polyethers such as polyethylene glycols, which are available under the trade de~igJ~tionc "Carbowax" from Union Carbide, Danbury, CT; "Voranol"
~om Dow Chemical Co., Mi~ n~l, MI; and "Pluracol E" from BASF Corp., Mount Olive, NJ; poly~lo~Jylene glycols, which are available under the trade de~igr ~tion~
30 "Pluracol P" from BASF Corp. and "Voranol" from Dow Chemical Co., Midland, .

MI; and polytc~ ncll.ylene oxides, which are available under the trade de~ a~;ol-~
"Polymeg" from QO Chemical Inc., Lafayetts, IN; "Poly THF" from BASF Corp., Mount Olive, NJ; and "Te~ hane" from DuPont, Wilmineton~ DE. IIydl oAyl fimr.tis~n~1 polyesters are available under the trade df ~ AI ;nm "Multranol" and "De~",ophene" from Miles, Inc., Pittsburgh, PA. Virtually all polylu,ell,ane formulations inco")oldle one or more catalysts. Tertiary amines and certain org~nomP~t~llic compounds, especially those based on tin, are most co. . .OI~
Co"~bi~ ;on~ of catalysts may be used to balance the polymer-ro- ~ rate.
EPOAY resins have an oxirane ring and are poly",c,i~ed by the ring ope.~i~lg.
Such epoxide resins include ,llonol"~,.ic epoxy resins and polymeric epoxy resins.
These resins can vary greatly in the nature of their backbones and su~stitupnt groups. For eY~mrlP,~ the backbone may be of any type normally ~ori~ted with epoxy resins and s~lbstituPnt groups thereon can be any group free of an active l~.yd~oge.l atom that is reactive with an oxirane ring at room le.~ u~e.
R~p,.,s_nlali~e exarnples of ~~cep~-'le sr~bstihlent groups include ~qlo~n~ ester groups, ether groups, s.ll~nate groups, ciloyane groups, nitro groups and phosl~hate groups. F~ ,les of some pr~fe.l ed epoxy resins include 2,2-bis[4-(2,3-epo,~ylulo?oxyphenol)l ropal~c (diglycidyl ether of bi~lJh~-ol A)] and conunel.,i lly available materials under the trade ~ie~ l;on~ "Epon 828", "Epon 1004", and "Epon 1001F", available from Shell Chemic~l Co., Houston, TX; "DER-331", "DER-332", and "DER-334" available from Dow Ch~mic~l Co., Midland, MI.
Other suitable epoxy resins include glycidyl ethers of phenol form~l~ehyde novolac (e.g., "DEN-431 " and "DEN-438" available from Dow Chemical Co., Midland, Ml). Other epoxy resins include those desc,ibed in U.S. Patent No. 4,751,138 (Tumey et al.).
Urea-aldehyde resins employed in binder p~;ul~or conlposiliolls ofthe present invention may be co,..~ ed of a reaction product of urea or any urea derivative and any aldehyde which are capable of being .~.rdeied coat~ble, have the capability of curing together at an accele.~led rate in the p. esence of a catalyst, 30 preferably a cocatalyst, and which afford an abrasive article with abrading pe. rv....~ ~ce acc~ ble for the int~nded use. Urea-formaldehyde resins are generally p.efe-.~d in the abrasive industry, as noted above, because oftheir availability, low cost, and ease of handling. Urea-aldehyde resins preferably are 30-95% solids, more preferably 60-80% solids, with a ViSCG..;ly ranging from about - 5 125 to about 1500 cps (Brookfield viscometer, number 3 spindle, 30 rpm 25~C) before ~ ition of water and catalyst and have molcc~ r weight (number average) of at least about 200, p.~fe.~l~r varying from about 200 to 700. Urea aldehyde resin useful for the present invention include those des~,.;l)ed in U.S. Patent No.
5,486,219 (Ford et al.).
A particularly plere.led urea-aldehyde resin for use in the present invention is that known under the trade de~ ;on AL3029R, from Borden Chemical. This is an l)nm~l~ified (i.e. CG~ S no furfural) urea-formaldehyde resin with these ch~ ~cteristics: 65% solids, viscosity (Brookfield, #3 spindle, 30 rpm 25~C) of 325 cps, a free formaldehyde content of 0.1-0.5%, and a mole ratio of fo-rm~ yde to urea ("F/U ratio") ranging from about 1.4:1.0 to about 1.6:1Ø
Urea resin binder p~.,u. ~or systems preferably employ a cocatalyst system.
The cocatalyst may consist çCcenti~lly of a Lewis acid, preferably ~ mimlm chloride (AICI3), and an organic or inorganic salt. A Lewis acid catalyst is defined simply as a compound which accepts an ele~llon pair, and p.t;rw~ly has an aqueous s ol~.lb;lity at 15~C of at least about 50 grams/cc.
Lewis acids (or compounds which behave as Lewis acids) which are p.l,f~,l.. d are ~I.. ;.. n chloride, iron (m) chloride, and copper (II) chloride. A
Lewis acid which is particularly prerelled is ~hlm~ m chloride in either its non-hydrated form (AICI3) or hexahydrate from (AICI36H20).
The Lewis acid is typically and preferably used in the binder precursor system at an amount ranging from about 0.1 to about 5.0 weight percent of the total weight of binder precursor, as a 20-30% solids aqueous solution. If ~ mim~m chloride (AICI3) is used, it has been found that 0.6 weight percent of a 28% solids a~leouC sol~tion of AIC13 gives preferable results.

.

CA 022~3~77 1998-11-0~

Acrylate resins include both monomeric and polymeric compounds that contain atoms of carbon, hydrogen and oxygen, and optionally, nitrogen and the halogens. Oxygen or nitrogen atoms or both are generally present in ether, ester, urethane, amide, and urea groups. Ethylenically unsaturated compounds preferably5 have a molecular weight of less than about 4,000 and are preferably esters made from the reaction of compounds containing aliphatic monohydroxy groups or aliphatic polyhydroxy groups and unsaturated carboxylic acids, such as acrylic acid, rnethacryiic acid, itaconic acid, crotonic acid, isocrotonic acid, maleic acid, and the like. Representative examples of acrylate resins include methyl meth~crylate, ethyl 10 methacrylate, ethylene glycol diacrylate, ethylene glycol t~ime~h~crylate~ hex~ne.liol diacrylate, triethylene glycol diacrylate, trimethylolpropane triacrylate, glycerol triacrylate, pentaerythritol triacrylate, pentaerythritol trimetl ~rylate, ~X pentaerythritol tetraacr~late and pentaerythritol tetramethacrylate,,~ Lh~
l unsaturated monom~, for example, styrene, divinylbenzene, vinyl toluene.
Acrylated isocyanurates are isocyanurate derivates having at least one pendant acrylate group, which are further described in U.S. Patent No. 4,652,274(Boettcher et al.). A prefel I ed acrylated isocyanurate is the triacrylate of tris(hydroxyethyl) isocyanurate.
Acrylated urethanes are diacrylate esters of hydroxy termin~ted isocyanate 20 extended polyesters or polyethers. Examples of commercially available acrylated urethanes include those available under the trade designations, "UVITHANE 782", "CMD 6600", "CMD 8400", and "CMD 8805", from Radcure Specialties, Inc., Atlanta, GA.
Acrylated epoxies are monoac~,~ylate and diacrylate esters of epoxy resins, 25 such as the diacrylate esters of bisphenol A epoxy resin. Examples of col.----efcially available acrylated epoxies include "CMD 3500", "CMD 3600", and "C~vID 3700", available from Radcure Specialties, Inc., Atlanta, GA.
Bismaleimide resins are further described in the ~ssi~nee~s U.S. Patent No.
5,314,513.

, .

In hd~1iSiQn to th~,...~os~ e resins, a hot melt resin may also be used For ~Y~mrlç, a binder precursor system may co~ ,e a hot melt ples~Jl~; 3e.l~ e adhesive which can be energy cured to provide a binder. In this ;..~l~n~e, because the binder precursor is a hot melt co-..pos;lion, it is particularly useful with porous S cloth, textile or fabric ba~l~in~c Since this binder precursor does not pel el.~le the i lt~ ices of the porous b. -L in~ the natural flPYihility and pliability of the backing is preserved F~ ..pl~.y hot melt resins are desc.;l,ed in U.S. Patent No 5,436,063 (Follett et al ) The hot melt binder precursor system may co~nç";se an epoxy-co~
10 material, a polyester co...~on.,nL, and an effective amount of an initiator for energy curing the binder More particularly, the binder precursor can co...~.;se from about 2 to 95 parts ofthe epoxy-col~lA;..;,~g l..ate,;al and, co.,~,s~,ondingly, from about 98 to S parts of the polyester co...pon~ t, as well as the .~ iator An optional hydroxyl-co..~ain.,.g m~t~ri~l having a hydroxyl fimctionslity greater than 1 may also lS be in~luded Plefelably, the polyester co...pone.ll has a Brookfield viscos;ly which eYcee~e 10,000 milliPascals at 121~C to 200,000, more pr~f~.ably from about 10,000 to S0,000, and most preferably from about 15,000 to 30,000 The polyester component may be the reaction product of a dicarboxylic acid s~lected from the group concictin~ of saturated alirh~tic dicarboxylic acids co~ o from 4 to 12 carbon atoms (and diester derivatives thereof) and aromatic dicarboxylic acids containing from 8 to 1 S carbon atoms (and diester derivatives thereof) and (b) a diol having 2 to 12 carbon atoms 2S Abrasive Particles Abrasive particles useful in the invention can be of any convention~l grade utilized in the formation of abrasive articles S~lit-blE abrasive particles can be formed of, for tA~ c', flint, garnet, ceria, ~l~lmimlm oxide (incl~tling fused and heat-treated ~l.lmimlm oxide), alumina zirconia (including fused ~Il)min~ ~conia as ~iccl~se~ for ~;A~IIi)ie, in U S Pat Nos. 3,781,172; 3,891,408; and 3,893,826, and CA 022S3s77 1998-11-OS

co.. P .;ially available from the Norton Company of Wol ce.. t~,r, MA, under the trade ~le~ on "NorZon"), ~ ,nl~, silicon carbide (jnf.lurling refractory coated silicon carbide as ~iQ-close~l, for exarnple, in U.S. Pat. No. 4,505,720 (Gabor et al.)), silicone nitride, alpha al-lmin~-based ceramic material (as ~iQ~Iose~ for example, in S U.S. Pat. Nos. 4,518,397 (~ e;l~ er et al.); 4,574,003 (Gerk et al.); 4,744,802 (Schwabel et al.); 4,770,671 (Monroe et al.); 4,881,951 (Wood et al.); and 5,011,508 (Wald et al.)), tit~ m diboride, boron carbide, t..~QtPn carbide, tit~ni~)m carbide, iron oxide, cubic boron nitride, and mixtures thereof. Diamond and cubic boron nitride abrasive in the form of grains may be monocrystalline or10 polycrystalline.
Abrasive particles may be individual abrasive grains or a~lo...- . ~tes of individual abrasive grains. Abrasive particles may have a particle size ranging from about 0.01 to 1500 mic.u~ te.~ typicallyb.,l~.cwl 1 to 1000 micr~ ,t~s As diQc~.~ced above, abrasive particles having a particle size of from about 0. ~ to less than 200 micl o,lleters, typically 0.1 to 120 l - olll~tel ~, are used frequently for lapping coated abrasives. The frequency (con~e.~n~Lion) ofthe abrasive particles on the backing depends on the desired ap~ lic~l;on and is within the purview ofthe skilled artisan. The abrasive p&- li~ s can be oriented or can be applied without o,i...-l~;ol-, depending upon the requ;ie,llents ofthe particular abrasive product.
The abrasive particles may be applied as an open or closed coat. A closed coat is one in which the abrasive particles completely cover the major surface of the be ~ing In an open coat, the abrasive particles cover from about 20 to 90 % of the major surface of the backing, typically from 40 to 70%.
An abrasive article ofthe present ill~,~nlion may contain a blend of ~~'laS;~e grains and diluent ~ licles. Diluent pa~ les can be sFle~1ed from the group cor.~ el;~g of: (1) an inorganic particle ~non-abrasive inorganic particle), (2) an organic particle, (3) an abrasive agglomerate cor.~;...ng abrasive grains, (4) acomposite diluent particle co..lAi~; .g a mixture of h~or~ ic palli(,les and a binder, (5) a composite diluent particle con~A~ g a mixture of organic particles and a 30 binder.

Non-abrasive inol~;~ic particles typically include materials having a Moh ha~ ess Iess than 6. The non-abrasive inOI~al)iC particles can include glilldill~, aids, fillers and the like, as described herein.
The particle size of diluent particles can range from about 0.01 to 1500 5 micrometers, typically b~ e~ 1 to 1000 mi~ olllet~ . The diluent particles mayhave the same particle size and particle size di;.hil,.lLion as the abrasive particles.
Alternatively, the diluent particles may have a di~.elll particle size and particle size d;sllil,~lion as the abrasive particles.

10 Optional Additives Optional additives, such as, for example, fillers (inclutl;~ grinding aids), fibers, slntict5ltir, agents, lubricants, wetting agents, surf~ct~ntc, p ~..e~ dyes, coupling agents, pl~ctici7p~rs~ release agents, and S~lslJc~ g agents, may be inr,l~lded in abrasive articles ofthe present invention. The amounts ofthese 15 materials can be sf~k~,led to provide the pro~c. Iies desired.
E~"l)les of useful fillers for this invention include: metal carbonates (such as calcium call,ol~ale (chalk, calcite, marl, travertine, marble and limP,sto~P,), calcium m~g~~SiUm carbonate, sodium carbonate, ~..&g..e~: ~n. c~l,onale), silica(such as quartz, glass beads, glass bubbles and glass fibers) silicates (such as talc, 20 clays, (~.~o..l.nolillonite) feldspar, mica, calcium silicate, calcium mP~t~ ir~te~
sodium ~ minosilir~te~ sodium silicate) metal sulfates (such as calcium sulfate,barium sulfate, sodium sulfate, ~ l;...i.ll sodium sulfate, ~IIlmin.lm sulfate),gypsum, vermiC~.litp wood flour, ~IIlminllm llih~dlale~ carbon black metal oxides (such as calcium oxide, ~IIll~i lll-l~ oxide, tit~nillm dioxide) and metal sulfites (such 25 as calcium sulfite). FY~mples of useful fillers also include silicon compounds, such as silica fiour, e.g., powdered silica having a particle size of from about 4 to 10 mm (available from Akzo Chemie America, Ch;r~o, IL), and calcium salts, such as calcium carbonate and calcium met~eili~qte (available under the trade des;gl-al ;one "Woll~etokllp" and "Wollastonite" from Nyco COIll~ , Willsboro, NY).

Examples of qntistvqtic agents inc}ude graphite, carbon black ~/An7 lil....
oxide, h~ n~s, and the like. These an~icl~;c agents are disclosed in U.S. PatentNos. 5,061,294; 5,137,542; and 5,203,884.
A courling agent can provide an association bridge b.,h~ n the binder and 5 the filler particles. ~ itionqlly the coupling agent can provide an qCSOriqtiOn bridge between the binder and the abrasive particles. Examples of coupling agents include silanes, ~ f C, and zircos~-min-q-tes There are various means to incorporate the coupl;..g agent. For eYqmrl~, the couplil~g agent may be added directly to the binder precursor, which is referred to as "insitu". The binder may 10 contain anywhere from about 0.01 to 3% by weight co~pling agent. Alternatively, the coupling agent may be applied to the surface of the filler particles. In still another embodiment, the c~ g agent is applied to the surface of the abrasive partides prior to being inco. ~ o. ale:d into the abrasive article. The abrasive particle may contain ~.~wl.~re from about 0.01 to 3% by weight co~rlil~ agent.
Aotiloadiog Component An qntilQ~~ine c~ )on~ ofthe present invention is present in a peripheral coating of an abrasive article and is capable of contqcti~ a workpiece. An antiloading col..i)one.ll of the present invention is a compound having a 20 hydrocarbon chain and a polar group. Antiloading co.,.pon.,.lts of the present invention include compounds of any of folllllllas 1 and 2 and ~...~lu- es thereof:

ll w~(x)p Pj~ R

wl.~,. ein R~ and R2 are in~eppn~ently OH or OR, R is an alkyl group, plerc;~abl~ CnH2n+l where n is 1 to 30, pi~fe.~bly 1 to 25 10, more pr~fe.~bly 1 to 2;
X is O, S, NH, or a divalent aliphqtic (inçl~ ing linear, branched, and cycloaliphatic) or aromatic linking group having 20 atoms or less and CG~ g carbon and, optionally, nitroge4 oxygen, phosphorus, and/or sulfur in the ~liphqtir.

_ wO 97/42006 PCT/USg7/04036 or aro-,-alic group or as a substituent to the ~lirhqtic or al~lllaliC group, X is preferably O;
p is 0 or 1, p,~r~lably 0; and W is an aLkyl group, which may be saturated or unsaturated, pl~lably W
has a formula CnH2~+l where n is 10 to 100, p,~;r~,ably 12 to 30, more pl~ably 18 to 22, or W is a fluorinated hydrocarbon having a formula C~F2m+,~ where a is 0 to 2m and m is 4 to 50, preferably 6 to 30, more preferably 8 to 20, wl..,.cm the alkyl group or the ~uo~ ted hydrocarbon may contain oxygen atoms in a backbone ofthe alkyl group or the fluorinated hydrocarbon, le~,e.,~ ely, in an 10 amount ranging from 1 to 1/2 a total number of carbon atoms present in the alkyl group or the h~.lroca l,on, i.e., 1 to n/2 in the case of CnH2~+l or 1 to m/2 in the case of CmH~F2nl+~ ~;
~--R3 W z_ wL~,.ch~ R3 and R4 intlepf -d~ ly are H or an allyl group, preferably CnH2~+1 where n is 1 to 30, preferably 1 to 10, more preferably 1 to 2;
Z is a monovalent anion, for example, H2PO4, HS04; NO3, Cl, Br, r, F, CH3SOi, H2PO3, CnH2n+lOPO3E~ CnH2~+lPO3H ~ whc.~,in n is 1 to 100, pl~ft;lably 1 to 30, more preferably 10 to 20; preferably Z is H2POi~ H2PO3, HSO4-, CH3SOi, preferably H2POi, H2PO3;
A is a divalent ~liph~tic (inrlu~in~ linear, Stancl.cd, and cyrloqlirh~tic) or aromatic linking group having 20 atoms or less and co~ ne carbon and, optionally, n~LIogen, oxygen, phnsphorus, and/or sulfur in the ~liph~tic or aromatic group or as a substitupnt to the ~liphqtic or aromatic group, with the proviso that the linking group is connPcted by a carbon atom to N of formula 2; when t =1, preferably A is C(=O), CH(CH3), C(=O)CH2, NHC(=O), OC(=O), OCH2, OCH2CH2, or OCH(CH3)CH2;
t is 0 or 1, preferably 0; and W is an alkyl group, which may be saturated or unsaturated, p~,f.,.~.bly W
has a formula CnH2"+~ where n is 10 to 100, prc;r~.dbly 12 to 30, more preferably 18 to 22, or W is a fluorinated Lyd~oc~bon having a formula C~ F2m+1 ~ where a is 0to 2m and m is 4 to 50, preferably 6 to 30, more preferably 8 to 20, wherein the5 alkyl group or the fluorinated hydrocarbon may contain oxygen atoms in a backbone of the alkyl group or the fluorinated hydrocarbon, re~e~ ely, in an amount ranging from 1 to 1/2 a total number of carbon atoms present in the alkylgroup or the hydrocarbon, i.e., 1 to n/2 in the case of C,~I2n+1 or 1 to mJ2 in the case of C"~I~F2,n+1.~
Preferably, the antiloading co~ ,one~.L of the present invention is any of octadecyl ph~ sphqte, docosyl phosphote, tetradecyl ph~ s~ h.~ c acid, hPY~decylphosphate, octadecyl phosphonic acid, heYq~ecyl phosphonic acid, octade~iy~ on~ phosphate, octade~ ni~ phssphite, h.oY~ecyl ammonium phosphq~P, hPYqdecylqmmonillm phosphiLe, docosylz~
1~ phssphqtP, docosyla~"noluum phosph;le, octadecyld".. ll.ylz~.. o~ m phosphate, and octadecyldi-,l~,~h~l-qmmoni~-m phosphite More p,~;re,ably, the qntilo"-~ing cG...I)on.".l is any of octadecyl phosrhstP" docosyl phosphate, tetradecyl phosph~ic acid, docosyl-q~mmoni~m phosphqtP" and octadecyld~nle~h phosphate Antiloading Component in a Peripheral Coating A peliphe~l coating may have the following plq~~mlont in an abrasive article: over a size coat, if a make coat and a size coat are present; over a make coat and abrasive particles, if only a make coat is plesenl, over an abrasive coating;
25 over abrasive co...pos;les; or over binders of a nonwoven or bonded abrasive article A pc.ii)h~,~dl coating is prepared from a p~ ,he.al conl~os;lion ccs...~ g an ~ntilo~in~ co."pollenl ofthe present i~ ,..lion The p.,.;~hc.~l composition may contain 100% by weight ~ntilo~Ain~ co",pone.ll or qntiloa~ing compolle.lt and 30 a liquid medillm The peripheral coating is subst~nti~lly free of a binder The phrase "subsl~ lly free of a binder" means herein that there is 5% or less by weight, typically 2% or less by weight, preferably 1% or less by weight, and more preferably 0% by weight, binder pl .,~,u. ~or present in the pc.;~ l con~po~ilion.
Generally, the amount of qntilor~i~ col~lpone.ll in a p.,.i?h.,.~l coating ranges from about 95 to lO0 % by weight, typically 98 to 100%, plerc-ably 99 to 100%, more preferably 100%, based on the dry coating weight ofthe pel;~h~ l colq,tir~
Of course, the p.,.iph~ l coating may also contain optional additives such as s~lnfq-ctq-nt~, plq~tiri7ers~ anti-static agents, wetting agents, anti-rs,~ agents, dyes, pi~m~nt~, and fillers. Typical examples of fillers are talc, silica, silicates and l O metal carbonates. These additives may be present in an amount to provide the desired benefit ~om the additive and should not affect loading plUpC~ lies achieved by the present invention.
The p~ k~ coating may Co~ JIi3c, in ~tliti-~n to the .,ntil~
cGllll.oncnl ofthe present invention, an ndtlitionql convenl ~r~l antiloading CCJIlllJOn~,.ll. Examples of conventi~-rql a ~ a~i~ cûlllpon~ include metal salts of fatty acids, for eY~mp'e zinc stearate, calcium stearate, and lithium stearate;
waxes; ~.1 ile, and the like.

Method of Applying an Antiloading Component An ~ntilo~ding colllponc.ll of the present invention is present in a puiph~
coating. The p.,.il)h~ l composition may also include a liquid .I.GdilJ~.. such as water or an organic solvent. In general, the pc.i~he,lal composition may co...l.. ;.~e from about l to about 100% by weight, preferably lO to 60% by weight, more pl~f~,.ably 15 to 40% by weight, ~ntil~a'irtg co...rû~ , and from about 0 to about 99% by weight liquid me~illm, pre~.a~l~ 40 to 90% by weight, more pl~,ftl~bly 60to 85% by weight.
The peliph~ l composition may be liquid-free. The term "liquid-free" as used herein refers to less than l weight % liquid ...e~i~.... rei,l,ecli~ely, that is, an eSs~nti~lly 100% ~ntiloading conli)on.,.lt system, with the c~ce~)tion that optional 30 additives may be inclllde~

-3 l -CA 022~3~77 1998-11-0~

A method of applying a peripheral composition co,l,p,is;ng 100 %
antiloading component (or antiloading co".ponent plus optional additives) which is li~uid-free includes melting the co~ oailion to form a hot melt composition, O~ ~,p 1~, c'~ ~
~co~f;'~he composition, for example, by coating, and cooling at room temperature5 (about 25~C) for 5 to 10 mimlt~ Alternatively, a peripheral composition comprising 100 % antiloading component (or antiloading component plus optional additives) may be applied by extrusion coating where the temperature of the extruder melts the peripheral composition and then a die coater is used to apply the peripheral composition. The applied peripheral composition is then cooled at room temperature (about 25~C) for 5 to 10 min~ltes-In another embodiment, an antiloading component of the present invention can be combined with a liquid medium including water and organic solvents to fo~n a peripheral composition. The antiloading component can form a solution with theliquid medium or can exist as a dispersion in the liquid medillm A pl~fe.led application comprises, as a peripheral composition, a dispersion of an antiloading component in water, preferably deionized water, or in THF. The liquid me~itlm generally is present in an amount ranging from about 0 to about 99% by weight, preferably 40 to 90% by weight, more preferably 60 to 85% by weight, based on the total wet weight of the peripheral composition.
The peripheral composition comprising an antiloading component and liquid medium can be applied by brushing or coating the composition on an abrasive article, for example, by roll coating, curtain co~tin~ die coating, spray coating, and the like, and then dried at a te~l~pe.alure which depends on the liquid medium sPlecte~ For example, the temperature generally ranges from about 20 to 120~C, 2S typically 40-100~C, preferably 60-80~C, for a period oftime generally ranging from about 3 minutes to 30 hours, typically from about 5 mi~utes to 10 hours, preferably 10 minlltes to two hours.
Suitable organic solvents include tetrahydrofuran, acetone, methyl ethyl ketone, toluene, methyl isobutyl ketone, ethanol, isopropanol, meth~nol, and glycol ether solvents.

-32- ~s -~

The dry coating weight ofthe ~.;phe.~l coating in any ~ lJGd;-.. l depPn~c upon the coated abrasive grade, that is the particle size of the abrasive particle. Typically, the coarser or the larger the abrasive particle is, the higher the coating weight will be. For a given grade, if the coating weight is too high, the 5 abrasive particles may be hidden by the periyhcral coating. If the coating weight is too low, then the optimal pe-rw~ ce of the resulting abrasive article may not beachieved. For eA~lllJle, as a ~ lPline~ a coating weight of about 1 to about 30 g/m2, typically 4 to about 12 g/m2, may be used with grade P400 abrasive particles;
a coating weight of about 1 to about 50 g/m2, typically 3 to about 15 g/m2, may be 10 used with grade P320 abrasive particles; a coating weight of about 1 to about 50 glm2, typically 7 to about 25 g/m2, may be used with grade P180 abrasive partides;
and a coating weight of about 1 to about 75 glm2, typically 9 to about 30 glm2, may be used with grade P120 abrasive particles.

15 Methods of Using Abrasive Articles An abrasive article of the present invention can be used for abrading various workpieces or subsllales in~lu~ine wood, wood-like ...~ lc such as fiber board and particle board, fiberglass, ~a-,l.shes, polyester CG ~ , stained surfaces, automotive body filler, ceramics, glass, paint inc~ ng latex and oil paint, primers 20 inrl~ n~ oil-based and water-based primers, and metals in~ i~ al.~ "
s:~: 'ess steel, and mild steel. As used herein the term "abrading" refers to grinding, polishing, surface removal, surface l~ g and the like.
A method of abrading a wu~C~ eCe incll~dçs cont~eting the w~"~ ece with a ph;~.h~ l portion or surface of an abrasive article, -with s~ c enl force (typically 25 more than about 1 kg/cm2) to abrade the w~l~'c~-ece while the p.,.i~)he.al portion or surface and wurhr-ece are moving in relation to each other. Either the workpieceor the abrasive article may be ~laliona,y.
As desc.ibed herein, a coated abrasive can be in the form of a belt, disc, sheet, or the like. In embo~liments in which the abrasive article is a cortin-lo.l~
30 abrasive belt, the choice of contact wheel, force employed, and abrasive belt speed derPn-ls on the desired rate of cut and the resulting surface finish on the workpiece, care being taken not to damage the workpiece. The contact wheel may be plain or serrated. The force between the abrasive article and the workpiece may range from 0.02 kg/cm to 60 kg/cm, typically and p,cre.~l~r from about 0.04 kg/cm to about 5 40 kg/cm. The belt speed may range from 300 meters per minute (m/min) to 3,1 00 m/min, more typically and preferably from about 900 m/min to about 2,200 m/min.

EXAMPLES
TEST METHODS
Schiefer Test This test provides a measure of the cut (material removed from a workpiece) of coated abrasive articles under dry con~itiQne (about 22~C and about 45% Relative Humidity).
A 10.2 cm ~ .. ,tel circular disc was cut from the ab.~;~e material tested and secured by a p~ a~ ~c-se..s;li./e double adhesive tape (cG.",ne,c;ally available from ~innP~ot~ Mining and ~m~r l....l,g Co..,~ , St. Paul, MN, under the trade ~ l;on "3M Industrial Tape #442") to a back-up pad. The back-up pad was secured to the driven plate of a ~.hiefer Abrasion Tester (available from 20 Frazier Precision Company, GailL~ bu~g, Maryland). Doughn.lt shaped ce~ 'ose acetate butyrate polymer wolk~:e~ 10.2 cm outside fl;~n~.,lf r, 5.24 inside rli~ r, 1.27 cm thick, available from Seelye Plastics, Mim~eapolis, MN, were employed as workpieces. The initial weight of each workpiece was ~ ecorded to the nearest milligram prior to mounting on the wo~k~ ce holder ofthe abrasion tester.
25 A 4.5 kg weight was placed on the abrasion tester weight pla~rullll and the .no~ d abrasive s~eci~ lowered onto the wolk~:eee and the --hine turned on. The m~hine was set to run for 500 cycles and then to automatically stop. After each 500 cycles of the test, the w-urk~.:ece was wiped free of debris and ~e;ghed. The cl.m.ll~tive cut for each 500-cycle test was the difference bclwccn the initial weight before each set of 500 cycles and the weight following each set of S00 cycles. The endpoint of the test was 2,000 cycles.

Dual Action (DA) Sanding Test/Off-~and Abrasion Test A paint panel, i.e., a steel substrate with an e-coat, primer, base coat, and clear coat typically used in automotive paints, was abraded in each case with coated abrasives made in acco~dance with the invention and with coated abrasives as colllp~alive c ~'es Each coated abrasive had a .1i~ .. ,t~ ~ of 15.2 cm and was attached to a random orbital sander (available under the trade deA;gn~;ol- "DAQ", 10 from National Detroit, Inc., Rockford, IL). The ~ _ding p~ le was about 0.2 kg/cm2, while the sander operated at about 60 PSI((~TOOL (413 kPa). The painted panels were purchased from ACT Company of ~jllr~ Mirhi~n The cut in grams was comr~lted in each case by w e~ g the prirner-coated ;~ L~ale beforeabrading and after abrading for a predet~,.l.lined time, for example, 1 or 3 m;mltes MATERIALS
The following materials were used in the exarnples (quotation marks inA~ e trade de,;~;o~
Table 1 -' - ' g C~ , P~cr - - or lU~ From Trade Which C~ . IsC
~vailable ( f ny) ~lad~ldihydrogenF~- .' 'R-- ~c,nc.,~'ran~ury, ~. "DV~ ' "
h_~de~l dihydro~en phc ,~ - '(, c, nc., - ~ y, ~ ~ "DV_~' r~
dodecyldih.. ~."_np~r "I ~ R . ~ lC., ~ . "DV~
(C,6H33O)2~O(OH)Aer ch 1: u- c Co., ~ _ waukee, Wl Cl2H250~(lJH)2A ;~rch ~', -~ Co., V_ waukee, WI
C,8H3,P~J(O~ )2 A t-~-AESAR . ohnson l-~att~ey, Watd Hill, MA
C~4H25~PO(OH)2 Alfa-AESAR Johnson Manhe Watd Hill, MA
tbutyl-PO(OH)2 Alfa-AESAR Johnson Manhey, Ward Hill, MA
~d~l dihydrogen p~ ,~1 2 Hatcros ~ '- Inc., Kansas City, KS "T-Mulz 717-95"
C,8H37NH3+ dihydtogen F~ P~
salt 'Contains a high percentage of monoalkyl ~ pr and some diaL~cyl ~ and ttace amounts of p~ acid and the co..~ g sta~ing alcohol.
2Contains more . ~ than "DV4771" and thus has a lower melting point.
*~r- ' ~e-- r' provided below.

P~ ~dLions:
Pre,~ ion 1 Octadecylamine dihydrogen l)hosphale salt 85% phosphoric acid (1 0 mole) was added to a solution of octade~iyla,.. --c (1 0 mole) in THF until the pH reached 5. The white pre ;I.it~le was filtered under reduced pr~ e with a water aspirator and then washed with water The white ple. ;I.iti le was d;spe.~Pd in water at 10% solids The white d;s~.c.~;on was walll~ed to a cloudy dispC.~;;)n at 80~C before coa~

EXAMPLES
Plepal~lion of E~a~n?les 1 to 11 Coated abrasive articles lepr~,..e.lla~ e of the present invention were pl ~,?~ed by applying an antiloading coating to a coated abrasive disc, lacking a supersize coat, which is cc.l.. c;ally available from Mil~ne~ola Mining and ~m~f~ctllring Company, St Paul, MN, under the trade dP~ ;Qn "3M 210U
Production A weight paper" The ~ iloa l;..g component, the dry coating weight ofthe coating co.~lAi..;ne the ~ntiloarlin~ cou.~,one.lt, the disc size, the tradede~ ion for the colll,lle.c;ally a~ le coated abrasive disc, and the mineral 20 grade for each e.L_ r~e are in~ic~ted in Table 2 The antiloading coatings of FY;....,-leS 1 to 8 and 10 and 11 were dissolved in T~ solvent (15 % solution) and applied to the coated abrasive disc by dr~.pp~...
The discs were then dried at 90~C for 20 minlltes The ~ntilo?~di~ coating of Fy~tnple 9 was col-,bll.ed with water (10%
25 solution) and applied with a brush The disc was air-dried at room t~nl~ ult (about 25~C) WO 97t42006 PCT/US97/04036 Table 2 F. p'~ ,, C-. . ' Dry Costing Disc Gr~de of No. Weight of Size A'). ~_ '~-' g (cm) Coating (~2) octadecyl l;h~ub ~ ph~ '' u~
h Aade~ 1. p~ ~ . Ib 1- ~ ~ ~ ' (CI ~H33C )2PO(OH) Cl2 I2so?o(JH)2 "' - ' > i, Cl8 I37''O(O~:k . C,4 ~29~O(G-~)2 tbutvl-POtO-~ 2 -~
x ~Lei~ ~ h u" .~ phosphate2 :Ø4~ " ~: "
" ~ -,*37~ ~3 O'~u2'l' ~ . 8.33 7~, "
0 Cl4E~2~l0(0~2 10.48 .~
11 octadec~ l.ub p~ r 10.48 ~ ~
-"DV47, 1"
"DV3956"
2"T-Mulz 71~-95~

Prepa, alion of COIl,~)al ~live FYqmpl ~ ~
Colll~,a~live Example A was co"l",e.cially available from Mh~nesola Mining and Mqmlfq ;ttlring Company, St. Paul, MN, under the trade designqtion "3M 210U Production A weight paper".
Conlpaldlive F~ ,les B and F were pre~ cd by applying calcium stearate as a dispersion in water (50% sol~lti~n), with a paint blush, to a coated abrasive product collllllcrcially available from Minn~.~otq. Mining and Mqnllfq~lrinp Company, St. Paul, MN~ under the trade designq~tiQn "3M 210U Productinn A
weight paper," and then drying at 88~C for 15 min-ltes. The calcium stearate 15 coating was similar to the calcium stearate coating of the coated abrasive product co....n~.~;ially available from M;-.i-r50l~ Mining and MP ~..r~ p Colllp&l~, St.Paul, MN, under the trade des~ ;on "3M 216U Production Fre-Cut A weight paper."

CA 022s3s77 1gs8-ll-os Table 3 Comp. A -' g DryDisc Size Gr~de of F. ,~' ~ C~. l'Coating(cm) A' ~ .
Weight of A '~~ g Coating (~m2) A none 0 0 7:
B calcium stearate 10.48 :0 ~: ' F calcium stearate 10.48 ' 0 '~l EAhIIIPIeS 1 to 8 and Col"pa,alive Exd.l.~l s A and B
Examples 1 to 8 and Co--",aluti~e F~m, '- s A and B were tested according 5 to the Schiefer Test. Three discs were tested for each ~iAa".ple and the average cut every 500 cycles up to and incl~lfling 2000 cycles were determined. The results are shown in Table 4.

Ta ~le 4 Structure Schiefer ~est Res llts Example Chain PolarGroup Cut Cut Cut Total Cutas LOading#
D~ After ARer ARer Cut % Of 500 1000 1500 (2000 Comp.
Cycles Cycles Cycles Cycles) Ex. A
Comp. Ex. A none none 0.' 52 o.ugS 1.436 1.930 100 3 Comp. Ex. B n-CI7H35 ~A.~' ~ . Ca1.: 992.690 3.977 5.188 269 Ex. 1 n-C,8H3, ~h~ . - 1.863 3.9355.7087.326 380 Ex. 2 n-C,6H33 ph~ P~ 1.892 3.7175.2606.338 328 2 Ex. 3 two n-C~6~33 ph ,D~ 1.063 1.9762.8183.624 1883.5 Ex. 4 n-C~2H2.; p~~ p~ 1.300 2.2923.1223.903 202 3 Ex. S n-C~8H3, phosphonic acid 0.9532.4673.877 5.313 275 3.5Ex. 6 n-C,4~9 ~ acid 1.661 3.3044.8966.230 323 Ex. 7 tbutyl F~ . ' . acid 0.498 0.9051.2471.579 82 2 Ex. 8 n~C~sH37 P~ 1.633 3.3794.4615.466 283 3 #: The loading scale is from 1 to 5. 1 is the best with lirnited loading and 5 is the worst with extensive loading seen visually; the e A~en~ loading usually i"., eases the weight of the abrasive article tested.

15 Example 9 and Co~ a.a~ eExampleF
Exarnple 9 and Co~"pal dlh~e Example F were tested according to the DA
Sander Test. The sanding was conducted down to the primer coat. The cut was WO 97/42006 PCT~US97/04036 det~l~nlned after 1 minute and after 3 min~ltes. Each ~ le was tested four times.
The st. ndard deviation and mean of the 3 minute cut results were ç-s-lclllsted The results are shown in Table 5. The dPcigr qtior- of "A", "B", "C", and "D" indicate each of the four tests for each eY-s-mrle~

Table S
F '- 1 Minute Cut 3 ~inute Cut Sbandard Mcan Cut as % ofn~ ) ( ) Dc~a~on Cbmp. Ex. F
A B C D A B C
Comp.Ex.F 2.-6 2.74 3.01 3.14 ~. 0 5.86 6.42 1.75 0.9 5.93 100 Ex.9 2. 1 3.09 3.11 2.89 ~.: 7 6.33 6.02 . .60 0.77 5.63 95 Examples 10 and 11 and Co-.,pala~h~e F.Y~mrle B
- F.Y-s-mplas 10 and 11 and Co.,.pa-a~i~re F-~ , le B were evaluated in the DA
10 Ssn-linp Test. The sanding was cQnducted down to the primer coat. The cut of Co."yal~live Example B was taken to be 100% and the cut for F.~ nples 10 and 11 . re CO~ ed to the 100% cut of Co.,lpa,a~ e Example B. The results are shown in Table 6.

~able 6 Example Desi~nation Cut 8S % of Comp. Ex. B
Comp. Ex. B 100 Ex. 10 140 Ex. 11 117

Claims (10)

1. WHAT IS CLAIMED IS:
2. 2. An abrasive article comprising (a) a backing having a mayor surface;
   (b) a plurality of abrasive particles;
   (c) a binder which adheres the plurality of abrasive particles to the major surface of the backing; and (d) a peripheral coating comprising an antiloading component of any of formulas 1 and 2 or mixtures thereof:
   
   wherein R1 and R2 are independently OH or OR, R is an alkyl group;
   X is O, S, NH, or a divalent aliphatic or aromatic linking group having 20 atoms or less and containing carbon and, optionally, nitrogen, oxygen, phosphorus, and/or sulfur in the aliphatic or aromatic group or as a substituent to the aliphatic or aromatic group;
   p is 0 or 1; and W is an alkyl group, or W is a fluorinated hydrocarbon having a formula C m Ha F2m+1-a where a is 0 to 2m and m is 4 to 50, wherein the alkyl group or the fluorinated hydrocarbon may contain oxygen atoms in a backbone of the alkyl group or the fluorinated hydrocarbon, respectively, in an amount ranging from 1 to 1/2 a total number of carbon atoms present in the alkyl group or the hydrocarbon, respectively; and wherein R3 and R4 independently are H or an alkyl group;
   Z- is a monovalent anion;
   A is a divalent aliphatic or aromatic linking group having 20 atoms or less and containing carbon and, optionally, nitrogen, oxygen, phosphorus, and/or sulfur in the aliphatic or aromatic group or as a substituent to the aliphatic or aromatic group, with the proviso that the linking group is connected by a carbon atom to N
   of formula 2;
   t is 0 or 1; and W is an alkyl group, or W is a fluorinated hydrocarbon having a formula C m Ha F2m-1-a where a is 0 to 2m and m is 4 to 50, wherein the alkyl group or the fluorinated hydrocarbon may contain oxygen atoms in a backbone of the alkyl group or the fluorinated hydrocarbon, respectively, in an amount ranging from 1 to 1/2 a total number of carbon atoms present in the alkyl group or the hydrocarbon, respectively.
   
   3. The abrasive article of claim 2 wherein the binder is a size coat overlaying the make coat and the plurality of abrasive particles wherein R1 and R2 are independently OH or OR, R is an alkyl group;
   X is O, S, NH, or a divalent aliphatic or aromatic linking group having 20 atoms or less and containing carbon and, optionally, nitrogen, oxygen, phosphorus, and/or sulfur in the aliphatic or aromatic group or as a substituent to the aliphatic or aromatic group;
   p is 0 or 1; and W is an alkyl group, or W is a fluorinated hydrocarbon having a formula C m H2 F2m+1-a where a is 0 to 2m and m is 4 to 50, wherein the alkyl group or the fluorinated hydrocarbon may contain oxygen atoms in a backbone of the alkyl group or the fluorinated hydrocarbon, respectively, in an amount ranging from 1 to 1/2 a total number of carbon atoms present in the alkyl group or the hydrocarbon, respectively; and wherein R3 and R4 independently are H or an alkyl group;
   Z is a monovalent anion;
   A is a divalent aliphatic or aromatic linking group having 20 atoms or less and containing carbon and, optionally, nitrogen, oxygen, phosphorus, and/or sulfur in the aliphatic or aromatic group or as a substituent to the aliphatic or aromatic group, with the proviso that the linking group is connected by a carbon atom to N
   of formula 2;
   t is 0 or 1; and W is an alkyl group, or W is a fluorinated hydrocarbon having a formula C m H a F2m+1-a where a is 0 to 2m and m is 4 to 50, wherein the alkyl group or the
3. 3. The abrasive article of claim 2 wherein the binder and the plurality of abrasive particles are present in an abrasive coating.
4. 4. The abrasive article of claim 2 wherein the binder and the plurality of abrasive particles are present in a plurality of abrasive composites.
5. 5. The abrasive article in accordance with claim 2 wherein the antiloading component is selected from the group consisting of octadecyl phosphate, docosyl phosphate, tetradecyl phosphonic acid, hexadecyl phosphate, octadecyl phosphonic acid, hexadecyl phosphonic acid, octadecylammonium phosphate, octadecylammonium phosphite, hexadecyl ammonium phosphate, hexadecylammonium phosphite, docosylammonium phosphate, docosylammonium phosphite, octadecyldimethylammonium phosphate, and octadecyldimethylammonium phosphite.
6. 6. The abrasive article in accordance with claim 2 wherein the antiloading component is present in the peripheral coating in an amount ranging from 95 to 100% by weight, based on a total weight of the peripheral coating.
7. A bonded abrasive comprising (a) a plurality of abrasive particles;
   (b) a binder adhering the plurality of abrasive particles together; and (c) a peripheral coating comprising an antiloading component of any of formulas 1 and 2 or mixtures thereof:
   
   wherein R1 and R2 are independently OH or OR, R is an alkyl group;
   X is O, S, NH, or a divalent aliphatic or aromatic linking group having 20 atoms or less and containing carbon and, optionally, nitrogen, oxygen, phosphorus, and/or sulfur in the aliphatic or aromatic group or as a substituent to the aliphatic or aromatic group;
   p is 0 or 1; and W is an alkyl group, or W is a fluorinated hydrocarbon having a formula C m H a F2m+1-a where a is 0 to 2m and m is 4 to 50, wherein the alkyl group or the fluorinated hydrocarbon may contain oxygen atoms in a backbone of the alkyl group or the fluorinated hydrocarbon, respectively, in an amount ranging from 1 to 1/2 a total number of carbon atoms present in the alkyl group or the hydrocarbon, respectively; and wherein R3 and R4 independently are H or an alkyl group;
   Z is a monovalent anion;
   A is a divalent aliphatic or aromatic linking group having 20 atoms or less and containing carbon and, optionally, nitrogen, oxygen, phosphorus, and/or sulfur in the aliphatic or aromatic group or as a substituent to the aliphatic or aromatic group, with the proviso that the linking group is connected by a carbon atom to N
   of formula 2;
   t is 0 or 1; and W is an alkyl group, or W is a fluorinated hydrocarbon having a formula C m Ha F2m+1-a where a is 0 to 2m and m is 4 to 50, wherein the alkyl group or the fluorinated hydrocarbon may contain oxygen atoms in a backbone of the alkyl group or the fluorinated hydrocarbon, respectively, in an amount ranging from 1 to 1/2 a total number of carbon atoms present in the alkyl group or the hydrocarbon, respectively.
8. 8. A nonwoven abrasive comprising (a) an open, lofty nonwoven substrate;
   (b) a plurality of abrasive particles;
   (c) a binder adhering the plurality of abrasive particles into and/or onto the open, lofty nonwoven substrate; and (d) a peripheral coating comprising an antiloading component of any of formulas 1 and 2 or mixtures thereof:
   
   wherein R1 and R2 are independently OH or OR, R is an alkyl group;
   X is O, S, NH, or a divalent aliphatic or aromatic linking group having 20 atoms or less and containing carbon and, optionally, nitrogen, oxygen, phosphorus, and/or sulfur in the aliphatic or aromatic group or as a substituent to the aliphatic or aromatic group;
   p is 0 or 1; and W is an alkyl group, or W is a fluorinated hydrocarbon having a formula C m H a F2m+1-a where a is 0 to 2m and m is 4 to 50, wherein the alkyl group or the fluorinated hydrocarbon may contain oxygen atoms in a backbone of the alkyl group or the fluorinated hydrocarbon, respectively, in an amount ranging from 1 to 1/2 a total number of carbon atoms present in the alkyl group or the hydrocarbon, respectively; and wherein R3 and R4 independently are H or an alkyl group;
   Z is a monovalent anion;
   A is a divalent aliphatic or aromatic linking group having 20 atoms or less and containing carbon and, optionally, nitrogen, oxygen, phosphorus, and/or sulfur in the aliphatic or aromatic group or as a substituent to the aliphatic or aromatic group, with the proviso that the linking group is connected by a carbon atom to N
   of formula 2;
   t is 0 or 1; and W is an alkyl group, or W is a fluorinated hydrocarbon having a formula C m Ha F2m+1-a where a is 0 to 2m and m is 4 to 50, wherein the alkyl group or the fluorinated hydrocarbon may contain oxygen atoms in a backbone of the alkyl group or the fluorinated hydrocarbon, respectively, in an amount ranging from 1 to 1/2 a total number of carbon atoms present in the alkyl group or the hydrocarbon, respectively.
9. 9. A method of making an abrasive article comprising:
   (a) providing a backing having at least one major surface;
   (b) applying a make coat binder precursor over the at least one major surface of the backing;
   (c) embedding a plurality of abrasive particles into and/or onto the make coat binder precursor;
   (d) at least partially curing the make coat binder precursor to form a make coat;
   (e) applying a size coat binder precursor (f) curing the size coat binder precursor to form a size coat (g) applying a peripheral composition which is substantially free of a binder over at least a portion of the size coat, said composition comprising an antiloading component of any of formulas 1 and 2 or mixtures thereof:
   
   wherein R1 and R2 are independently OH or OR, R is an alkyl group;
   X is O, S, NH, or a divalent aliphatic or aromatic linking group having 20 atoms or less and containing carbon and, optionally, nitrogen, oxygen, phosphorus, and/or sulfur in the aliphatic or aromatic group or as a substituent to the aliphatic or aromatic group;
   p is 0 or 1; and W is an alkyl group, or W is a fluorinated hydrocarbon having a formula C m Ha F2m+1-a where a is 0 to 2m and m is 4 to 50, wherein the alkyl group or the fluorinated hydrocarbon may contain oxygen atoms in a backbone of the alkyl group or the fluorinated hydrocarbon, respectively, in an amount ranging from 1 to 1/2 a total number of carbon atoms present in the alkyl group or the hydrocarbon, respectively; and wherein R3 and R4 independently are H or an alkyl group;
   Z is a monovalent anion;
   A is a divalent aliphatic or aromatic linking group having 20 atoms or less and containing carbon and, optionally, nitrogen, oxygen, phosphorus, and/or sulfur in the aliphatic or aromatic group or as a substituent to the aliphatic or aromatic group, with the proviso that the linking group is connected by a carbon atom to N
   of formula 2;
   
   t is 0 or 1; and W is an alkyl group, or W is a fluorinated hydrocarbon having a formula C m Ha F2m+1-a where a is 0 to 2m and m is 4 to 50, wherein the alkyl group or the fluorinated hydrocarbon may contain oxygen atoms in a backbone of the alkyl group or the fluorinated hydrocarbon, respectively, in an amount ranging from 1 to 1/2 a total number of carbon atoms present in the alkyl group or the hydrocarbon, respectively; and (h) drying the composition to form a peripheral coating.
10. 10. The method in accordance with claim 9 wherein the antiloading component is selected from the group consisting of octadecyl phosphate, docosyl phosphate, tetradecyl phosphonic acid, hexadecyl phosphate, octadecyl phosphonicacid, hexadecyl phosphonic acid, octadecylammonium phosphate, octadecylammonium phosphite, hexadecyl ammonium phosphate, hexadecylammonium phosphite, docosylammonium phosphate, docosylammonium phosphite, octadecyldimethylammonium phosphate, and octadecyldimethylammonium phosphite.