초록 ▼

The present invention relates to a coated abrasive article containing abrasive agglomerates based on target cores that provide an extended surface. Target cores are defined as geometric shapes, e.g., spherical, rectangular, tetrahedral, conical, cylindrical, pyramidal or combinations and mixtures th

The present invention relates to a coated abrasive article containing abrasive agglomerates based on target cores that provide an extended surface. Target cores are defined as geometric shapes, e.g., spherical, rectangular, tetrahedral, conical, cylindrical, pyramidal or combinations and mixtures thereof. The preferred cores are porous structures with their own abrasive capacity as a grinding aid element. They are bonded on substrates, e.g., textile fabrics, plastic films, saturated or no treated papers, vulcanized fibers, non-wovens and mixtures thereof to produce extended surfaces on which are deposited the working abrasive particles, e.g., aluminum oxide, silicon carbide, zirconia alumina, ceramic aluminum oxide and mixtures thereof, through an electrostatic field to improve performance capabilities. The electrostatic field promotes orientation of the deposited grains around the cores with exposed sharp edges over the extended area, causing as a secondary effect the compacting of the abrasive grains. The abrasive grains are agglomerated in situ via nucleation of the surface of the target cores during the coated abrasive manufacturing process. Incorporation of the abrasive particles on the interstices between target cores also produces increased life of the coated abrasive article. The invention includes the method of manufacturing the abrasive article by forming the agglomerated particles in situ during the manufacturing process.

대표청구항 ▼

1. A coated abrasive article, comprising: a backing having a major surface;a plurality of agglomerates adhered to said major surface, said agglomerates formed in situ on said backing during the process of manufacturing said coated abrasive article by nucleation of a plurality of abrasive particles o

1. A coated abrasive article, comprising: a backing having a major surface;a plurality of agglomerates adhered to said major surface, said agglomerates formed in situ on said backing during the process of manufacturing said coated abrasive article by nucleation of a plurality of abrasive particles on a plurality of target cores previously adhered to said major surface of said backing, said target cores being porous structures having an abrasive capacity as a grinding aid element; anda pre-make, a make and a size coat, each said coat comprising an organic resin, wherein said pre-make and make coats bind said target cores to said working surface of said backing and wherein said make and size coats bind said abrasive particles to said target cores to form said agglomerates. 2. The coated abrasive article of claim 1 further comprising a top coat over said size coat. 3. The coated abrasive article of claim 1 wherein said target cores range is size from about 50 to about 5000 microns, said abrasive particles range is size from about 3 to about 2000 microns and the size ratio of said target cores to said abrasive particles is about 1-3:1. 4. The coated abrasive article of claim 1 wherein said target cores are in the form of shaped structures selected from the group consisting of spheres, cylinders, cubes, pyramids, tetrahedrons and other polyhedral shapes. 5. The coated abrasive article of claim 1 wherein said target cores are selected from the group consisting of alpha alumina with different percentages of alpha alumina between about 95% to about 99.9%, alumina zirconia, silica, titanium dioxide, glass, micro natural stones, polyethylene, polypropylene, polystyrene, other polymers and materials having a hardness of at least about 4 on Mohs scale and mixtures thereof. 6. The coated abrasive article of claim 1 wherein said abrasive particles are selected from the group consisting of fused brown and white aluminum oxide, heat treated aluminum oxide, silicon carbide, zirconia alumina, ceramic aluminum oxide, cubic boron nitride, garnet, gypsum, talc, calcium oxide, aluminum oxide, calcium silicate, glass bubbles, gypsum, talc, calcium oxide, aluminum oxide, calcium silicate, diatomaceous earths, materials having a hardness of at least about 7 on Mohs scale and mixtures thereof. 7. The coated abrasive article of claim 1 wherein said agglomerates are distributed on said backing in regular cell patterns forming shapes selected from the group consisting of circles, ellipses, triangles, squares, rectangles, rhombuses, other polygonal shapes and combinations thereof. 8. The coated abrasive article of claim 1 wherein said pre-make, make and size coats are selected from the group consisting of phenolic resins, urea-formaldehyde resins, melamine-formaldehyde resins, epoxy resins, acrylic resins, urethane resins, alkyd resins and mixtures thereof and may be the same or different. 9. The coated abrasive article of claim 1 wherein: said backing is selected from the group consisting of treated textile fabrics made from natural and synthetic yarns, vulcanized fibers, non-wovens, papers, saturated papers, polymeric extruded films, polymeric foams, paper/cloth combinations, mesh, stitch-bonded and combinations thereof;said target cores are selected from the group consisting of alpha alumina with different percentages of alpha alumina between about 95% to about 99.9%, alumina zirconia, silica, titanium dioxide, glass, micro natural stones, polyethylene, polypropylene, polystyrene, other polymers and materials having a hardness of at least about 4 on Mohs scale and mixtures thereof; andsaid abrasive particles are selected from the group consisting of fused brown and white aluminum oxide, heat treated aluminum oxide, silicon carbide, zirconia alumina, ceramic aluminum oxide, cubic boron nitride, garnet, gypsum, talc, calcium oxide, aluminum oxide, calcium silicate, glass bubbles, gypsum, talc, calcium oxide, aluminum oxide, calcium silicate, diatomaceous earths, other materials having a hardness of at least about 7 on Mohs scale and mixtures thereof; andsaid pre-make, make and size coats are each selected from the group consisting of phenolic resins, urea-formaldehyde resins, melamine-formaldehyde resins, epoxy resins, acrylic resins, urethane resins, alkyd resins and mixtures thereof and may be the same or different, wherein said pre-make and make coats bind said target cores to said working surface of said backing and wherein said make and size coats bind said abrasive particles to said target cores to form said agglomerates. 10. A method for manufacturing a coated abrasive article, comprising: selecting a backing having a first surface;applying to said first surface a pre-make coat comprising an organic resin;depositing a plurality of target cores onto said resin-coated first surface;at least partially curing said pre-make coat to adhere said target cores to said backing;applying a make coat comprising an organic resin over said at least partially cured pre-make coat, said target cores and said backing;depositing a plurality of abrasive particles onto said make coat;at least partially curing said make coat to form a plurality of agglomerates in situ on said first surface of said backing by nucleation of said abrasive particles on said target cores previously adhered to said backing;applying a size coat comprising an organic resin over said at least partially cured make coat and agglomerates; andcuring said size, make and pre-make coats. 11. The method of claim 10 further comprising applying a top coat over said size coat and curing said top coat. 12. The method of claim 10 wherein said target cores are in the form of shaped structures selected from the group consisting of spheres, cylinders, cubes, pyramids, tetrahedrons and other polyhedral shapes. 13. The method of claim 10 wherein said target cores are selected from the group consisting of alpha alumina with different percentages of alpha alumina between about 95% to about 99.9%, alumina zirconia, silica, titanium dioxide, glass, micro natural stones, polyethylene, polypropylene, polystyrene, other polymers and materials having a hardness of at least about 4 on Mohs scale and mixtures thereof and wherein said target cores range in size from about 50 to about 5000 microns. 14. The method of claim 13 wherein said abrasive particles are selected from the group consisting of fused brown and white aluminum oxide, heat treated aluminum oxide, silicon carbide, zirconia alumina, ceramic aluminum oxide, cubic boron nitride, garnet, gypsum, talc, calcium oxide, aluminum oxide, calcium silicate, glass bubbles, gypsum, talc, calcium oxide, aluminum oxide, calcium silicate, diatomaceous earths, materials having a hardness of at least about 7 on Mohs scale and mixtures thereof and wherein said abrasive particles range is size from about 3 to about 2000 microns and the size ratio of said target cores to said abrasive particles is about 1-3:1. 15. The method of claim 14 wherein said pre-make, make and size coats are selected from the group consisting of phenolic resins, urea-formaldehyde resins, melamine-formaldehyde resins, epoxy resins, acrylic resins, urethane resins, alkyd resins and mixtures thereof and may be the same or different. 16. The method of claim 10 wherein said target cores and said abrasive particles are deposited using a method selected from the group consisting of gravity and electrostatic deposition methods and may be the same or different. 17. The method of claim 10 wherein said agglomerates are distributed on said backing in regular cell patterns forming shapes selected from the group consisting of circles, ellipses, triangles, squares, rectangles, rhombuses, other polygonal shapes and combinations thereof. 18. The method of claim 10 wherein said pre-make, make and size coats are applied by a technique selected from the group consisting of spray coating, roll coating, die coating, powder coating, curtain coating and knife coating. 19. The method of claim 10 wherein said curing is achieve by subjecting said abrasive article to an energy source selected from the group comprising heat transfer, ultraviolet light or an electron beam. 20. The method of claim 19 wherein said curing is achieved by heating to a temperature of about 60° C. to about 150° C. 21. A coated abrasive article made by a process, comprising: selecting a backing having a first surface;applying to said first surface a pre-make coat comprising an organic resin;depositing a plurality of target cores onto said resin-coated first surface;at least partially curing said pre-make coat to adhere said target cores to said backing;applying a make coat comprising an organic resin over said at least partially cured pre-make coat, said target cores and said backing;depositing a plurality of abrasive particles onto said make coat;at least partially curing said make coat to form a plurality of agglomerates in situ on said first surface of said backing by nucleation of said abrasive particles on said target cores previously adhered to said backing;applying a size coat comprising an organic resin over said at least partially cured make coat and agglomerates; andcuring said size, make and pre-make coats. 22. The coated abrasive article of claim 21 wherein said process further comprises applying a top coat over said size coat and curing said top coat. 23. The coated abrasive article of claim 21 wherein said target cores range is size from about 50 to about 5000 microns, said abrasive particles range is size from about 3 to about 2000 microns and the size ratio of said target cores to said abrasive particles is about 1-3:1. 24. The coated abrasive article of claim 21 wherein said target cores are in the form of shaped structures selected from the group consisting of spheres, cylinders, cubes, pyramids, tetrahedrons and other polyhedral shapes. 25. The coated abrasive article of claim 21 wherein said target cores are selected from the group consisting of alpha alumina with different percentages of alpha alumina between about 95% to about 99.9%, alumina zirconia, silica, titanium dioxide, glass, micro natural stones, polyethylene, polypropylene, polystyrene, other polymers and materials having a hardness of at least about 4 on Mohs scale and mixtures thereof and wherein said target cores range in size from about 50 to about 5000 micronsw. 26. The coated abrasive article of claim 25 wherein said abrasive particles are selected from the group consisting of fused brown and white aluminum oxide, heat treated aluminum oxide, silicon carbide, zirconia alumina, ceramic aluminum oxide, cubic boron nitride, garnet, gypsum, talc, calcium oxide, aluminum oxide, calcium silicate, glass bubbles, gypsum, talc, calcium oxide, aluminum oxide, calcium silicate, diatomaceous earths, materials having a hardness of at least about 7 on Mohs scale and mixtures thereof and wherein said abrasive particles range is size from about 3 to about 2000 microns and the size ratio of said target cores to said abrasive particles is about 1-3:1. 27. The coated abrasive article of claim 26 wherein said pre-make, make and size coats are selected from the group consisting of phenolic resins, urea-formaldehyde resins, melamine-formaldehyde resins, epoxy resins, acrylic resins, urethane resins, alkyd resins and mixtures thereof and may be the same or different. 28. The coated abrasive article of claim 21 wherein said target cores and said abrasive particles are deposited using a method selected from the group consisting of gravity and electrostatic deposition methods and may be the same or different. 29. The coated abrasive article of claim 21 wherein said agglomerates are distributed on said backing in regular cell patterns forming shapes selected from the group consisting of circles, ellipses, triangles, squares, rectangles, rhombuses, other polygonal shapes and combinations thereof. 30. The coated abrasive article of claim 21 wherein said pre-make, make and size coats are applied by a technique selected from the group consisting of spray coating, roll coating, die coating, powder coating, curtain coating and knife coating. 31. The coated abrasive article of claim 21 wherein said curing is achieve by subjecting said abrasive article to an energy source selected from the group comprising heat transfer, ultraviolet light or an electron beam. 32. The coated abrasive article of claim 31 wherein said curing is achieved by heating to a temperature of about 60° C. to about 150° C.