Coated abrasives having aggregates

Patent metadata

Field	Value
Publication number	US-11148255-B2
Application number	US-201816230084-A
Country	US
Kind code	B2
Filing date	Dec 21, 2018
Priority date	Dec 27, 2017
Publication date	Oct 19, 2021
Grant date	Oct 19, 2021

Abstract

The present disclosure relates generally to coated abrasive articles that include a grinding aid aggregates in a make coat, a size coat, a supersize coat, or combinations thereof, as well as methods of making coated abrasive articles.

First claim

What is claimed is:

1. A coated abrasive article, comprising:
a backing substrate;
a polymeric make coat binder composition disposed on the backing substrate;
a plurality of abrasive particles disposed on or in the make coat binder composition;
a polymeric size coat composition disposed over the make coat composition; and
a plurality of grinding aid aggregates comprising a mixture of polymeric binder composition and a grinding aid composition, wherein the grinding aid aggregates are disposed on the make coat composition, on the size coat composition, or a combination thereof, wherein the grinding aid composition comprises potassium tetrafluoroborate (KBF 4 ), cryolite (Na 3 AlF 6 ), sodium ferrifluoride (Na 3 FeF 6 ), sodium hexafluorostrontium (Na 2 SrF 6 ), ammonium hexafluorophosphate (NH 4 PF 6 ), calcium fluoride (CaF 2 ), calcium phosphate (Ca 3 (PO 4 ) 2 ), magnesium sulfate (MnSO 4 ), lithium carbonate (Li 2 CO 3 ), potassium aluminum fluoride (K 3 AlF 6 ), or a combination thereof;
wherein the grinding aid aggregates comprise:
60-99 wt % of the grinding aid composition; and
1-40 wt % of the polymeric binder composition;

wherein the grinding aid aggregates are disposed to have an average particle height (H GAA ) as measured from the backing substrate, wherein the abrasive particles are disposed to have an average particle height (H ABR ) as measured from the backing substrate, and wherein the ratio of H GAA /H ABR ranges from 0.5 to 10; and
wherein the grinding aid aggregates have a total cross-sectional area (A GAA ), wherein the abrasive particles have an a total cross-sectional area (A ABR ), and wherein the ratio of A ABR /A GAA ranges from 1 to 1000.

2. The coated abrasive of claim 1 , wherein the grinding aid aggregates are disposed on the make coat composition.

3. The coated abrasive of claim 1 , wherein the grinding aid aggregates are disposed on the size coat composition.

4. The coated abrasive of claim 1 , wherein the grinding aid aggregates are disposed on the make coat composition and on the size coat composition.

5. The coated abrasive of claim 2 , wherein the grinding aid aggregates are disposed among and between the abrasive particles.

6. The coated abrasive of claim 3 , wherein the grinding aid aggregates are disposed among and between the abrasive particles.

7. The coated abrasive of claim 4 , wherein the grinding aid aggregates are disposed among and between the abrasive particles, above the abrasive particles, or a combination thereof.

8. The coated abrasive article of claim 1 , wherein the ratio of H GAA /H ABR ranges from 1 to 5.

9. The coated abrasive article of claim 1 , wherein the grinding aid aggregates have a particle size ranging from 0.1 mm to 5 mm.

10. The coated abrasive article of claim 9 , wherein the abrasive particles have an average particle size ranging from 0.1 mm to 5 mm.

11. The coated abrasive article of claim 1 , wherein the total weight of the grinding aid aggregates and the abrasive particles comprises:
80-99 wt % of the abrasive particles; and
1-20 wt % of the grinding aid aggregates.

12. The coated abrasive of claim 1 , wherein the grinding aid aggregate polymeric binder composition comprises a phenolic polymeric composition, a phenolic resole composition, a urea formaldehyde composition, a urethane composition, an epoxy composition a polyimide composition, a polyamide composition, a polyester composition, an acrylate composition, a protein based composition, a starch based composition, or any combination thereof.

13. The coated abrasive of claim 12 , further comprising a supersize coat composition disposed over the size coat.

14. The coated abrasive of claim 13 , wherein the supersize coat comprises a mixture of polymeric binder composition and a grinding aid composition, an anti-loading composition, or a combination thereof.

15. The coated abrasive of claim 14 , wherein the supersize coat composition comprises:
75-99 wt % of the grinding aid composition, the anti-loading composition, or a combination thereof; and
1-25 wt % of the polymeric binder composition.

16. The coated abrasive of claim 14 , wherein the grinding aid composition of the supersize coat comprises potassium tetrafluoroborate (KBF 4 ), cryolite (Na 3 AlF 6 ), sodium ferrifluoride (Na 3 FeF 6 ), sodium hexafluorostrontium (Na 2 SrF 6 ), ammonium hexafluorophosphate (NH 4 PF 6 ), calcium fluoride (CaF 2 ), calcium phosphate (Ca 3 (PO 4 ) 2 ), magnesium sulfate (MnSO 4 ), lithium carbonate (Li 2 CO 3 ), potassium aluminum fluoride (K 3 AlF 6 ), or a combination thereof.

17. The coated abrasive of claim 14 , wherein the polymeric binder composition of the supersize coat comprises an acetate composition, such as polyvinyl acetate; a phenolic polymeric composition, such as a phenolic resole composition; a urea formaldehyde composition; melamine resin composition; a urethane composition; an epoxy composition; a polyimide composition; a polyamide composition; a polyester composition; an acrylate composition, such as a UV curable acrylate, or a zinc cross-linked acrylic composition; a rubber composition, such as a styrene butadiene rubber; a protein based composition; a starch based composition, or a combination thereof.

18. The coated abrasive of claim 1 , wherein the grinding aid composition is potassium tetrafluoroborate (KBF 4 ).

Assignees

• Saint Gobain Abrasives Inc
• Saint Gobain Abrasifs Sa

Inventors

• Wang Jianna
• Kung Shih-Chieh
• Iyengar Sujatha K
• Yener Doruk O
• Everts Darrell K

Classifications

• C09D131/04

  Homopolymers or copolymers of vinyl acetate · CPC title

• B24D3/342

  incorporated in the bonding agent · CPC title

• B24D3/346

  utilised during polishing, or grinding operation · CPC title

• B24D3/28

  Resins {or natural or synthetic macromolecular compounds (B24D3/22 takes precedence)} · CPC title

• B24D3/004

  with special coatings · CPC title