Rigid backsize to prevent fiber disc curling

Patent metadata

Field	Value
Publication number	US-12059773-B2
Application number	US-202016953427-A
Country	US
Kind code	B2
Filing date	Nov 20, 2020
Priority date	Dec 31, 2019
Publication date	Aug 13, 2024
Grant date	Aug 13, 2024

Abstract

Systems and methods include providing a coated abrasive article with a substrate formed from a plurality of hygroscopic fibers, an abrasive layer comprising a make coat, a size coat, a supersize coat, or combinations thereof disposed on a first side of substrate, and an anti-curl layer disposed on a second side of the substrate. The polymer-based anti-curl layer allows the coated abrasive article to achieve a change in curl between −5 millimeters and 25 millimeters, the change in curl being expressed as the curl of the coated abrasive article in millimeters at 90% relative humidity minus the curl of the coated abrasive article in millimeters at 20% relative humidity. The coated abrasive article exhibits substantially no loss of grinding performance, burst speed, or a combination thereof as compared to coated abrasive articles free of the anti-curl layer.

First claim

What is claimed is:

1. A coated abrasive article comprising:
a substrate comprising a plurality of hygroscopic fibers;
an abrasive layer disposed on a first side of the substrate; and
an anti-curl layer disposed on a second side of the substrate, wherein the coated abrasive article comprises a change in curl between −5 millimeters and 25 millimeters, wherein the change in curl is expressed as the curl of the coated abrasive article in millimeters at 90% relative humidity minus the curl of the coated abrasive article in millimeters at 20% relative humidity, wherein the anti-curl layer comprises a weight of at least 9.0 lb./ream and not greater than 25 lb./ream, wherein the anti-curl layer comprises a majority of urea-formaldehyde, and wherein the abrasive layer comprises a weight of phenol formaldehyde polymer, and the ratio of the weight of the urea formaldehyde polymer of the anti-curl layer is at least 10% to not greater than 100% of the weight of the phenol formaldehyde polymer of the abrasive layer.

2. The coated abrasive article of claim 1 , wherein the coated abrasive article comprises a normalized change in curl percentage between −2.8% and 14.1%.

3. The coated abrasive article of claim 1 , wherein the abrasive layer comprises a make coat having a plurality of abrasive particles disposed on or in a polymeric binder comprising phenol formaldehyde, urea formaldehyde, UV-curable polymers, epoxy, acrylic, unsaturated polyester, or a combination thereof.

4. The coated abrasive article of claim 3 , wherein the abrasive layer comprises a size coat disposed over the make coat, a supersize coat disposed over the size coat, or any combination thereof.

5. The coated abrasive article of claim 1 , wherein the plurality of hygroscopic fibers comprises vulcanized fibers, leatheroid, or a combination thereof.

6. The coated abrasive article of claim 1 , wherein the substrate comprises a thickness of at least 0.60 millimeters.

7. The coated abrasive article of claim 6 , wherein the substrate comprises a thickness of not greater than 2.00 millimeters.

8. The coated abrasive article of claim 1 , wherein the anti-curl layer further comprises, UV-curable polymers, epoxy, acrylic, unsaturated polyester, latex suspension, fillers, or a combination thereof.

9. The coated abrasive article of claim 1 , wherein the anti-curl layer further comprises essentially of urea formaldehyde and fillers.

10. The coated abrasive article of claim 1 , wherein the anti-curl layer comprises a weight of at least 10.0 lb./ream.

11. The coated abrasive article of claim 1 , wherein the anti-curl layer comprises a thickness of at least 0.03 millimeters.

12. The coated abrasive article of claim 11 , wherein the anti-curl layer comprises a thickness of not greater than 0.2 millimeters.

13. The coated abrasive article of claim 12 , wherein the thickness of the anti-curl layer is not greater than 0.06 millimeters.

14. The coated abrasive article of claim 12 , wherein the anti-curl layer comprises a thickness of at least 0.07 millimeters to not greater than 0.175 millimeters.

15. The coated abrasive article of claim 1 , wherein the abrasive layer comprises a weight of a make coat and a size coat, wherein the anti-curl layer comprises a weight, and wherein the ratio of the weight of the anti-curl layer is at least 10% to 100% of the weight of the make and size coats of the abrasive layer.

16. The coated abrasive article of claim 15 , wherein the abrasive layer comprises a weight of phenol formaldehyde polymer, and the ratio of the weight of the urea formaldehyde-containing anti-curl layer is at least 10% to not greater than 100% of the weight of the make and size coats of the abrasive layer.

17. The coated abrasive article of claim 1 , wherein the anti-curl layer adjusts the mechanical center of the coated abrasive article to be between a central 50% of the substrate.

Assignees

• Saint Gobain Abrasives Inc
• Saint Gobain Abrasifs Sa

Inventors

• Coogan Timothy Jerome
• Peet Jeffrey H
• Yener Doruk O
• Lester Charles G
• Everts Darrell K
• Ma Yunshang

Classifications

• B24B37/22

  characterised by a multi-layered structure · CPC title

• B24B37/24

  characterised by the composition or properties of the pad materials · CPC title

• B24D3/20

  and being essentially organic · CPC title

• B24D3/344

  the bonding agent being organic · CPC title

• B24D3/004

  with special coatings · CPC title