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    • 专利摘要:
    STRUCTURED ABRASIVE ARTICLE AND METHOD OF USE OF THE SAME. The structured abrasive article includes a support layer that has a structured abrasive layer disposed on and attached to it. The structured abrasive layer includes shaped abrasive composites that comprise abrasive particles and non-ionic polyether surfactants dispersed in a cross-linked polymeric binder. Abrasive particles have an average particle size of less than 10 micrometers. The non-ionic polyether surfactant is not covalently bound to the cross-linked polymeric binder and is present in an amount of 2.5 to 3.2 percent by weight, based on the total weight of the shaped abrasive composites. Structured abrasive articles are useful for abrasion of a workpiece.
    公开号:BR112012005697B1
    申请号:R112012005697-2
    申请日:2010-04-01
    公开日:2021-01-05
    发明作者:Edward J. Woo；Scott R. Culler；Paul D. Graham；Jimmie R. Baran Jr
    申请人:3M Innovative Properties Company；
    IPC主号:
    专利说明:

    Background
    [001] The finishing and repair of glossy surfaces such as paints and finishing resins for automotive applications, lacquer finishes, glossy plastics, and the like is commonly done using a two-step method. First, the surface area to be finished or repaired is sanded with an abrasive article, in a second step, the sanded surface is polished by smoothing with the use of a polishing compound.
    [002] Structured abrasive articles, that is, abrasive articles that have a plurality of shaped abrasive composites attached to a backing layer, are widely used in the first abrasion step. During abrasion processes using structured abrasive articles, a liquid such as water or a cutting fluid is added to the abrasion interface to extend the life of the structured abrasive article. In the case of water, a surfactant is also often used. summary
    [003] In one aspect, the present description features a structured abrasive article comprising: a support layer containing two opposing main surfaces, and a structured abrasive layer disposed on and attached to a first main surface, the structured abrasive layer comprising abrasive composites conformed, and the conformed abrasive composites comprise abrasive particles and non-ionic polyether surfactant dispersed in a cross-linked polymeric binder, with the abrasive particles having an average particle size of less than 10 micrometers, with the nonionic polyether surfactant it is not covalently bound to the cross-linked polymeric binder, and the non-ionic polyether surfactant is present in an amount of 2.5 to 3.5 percent by weight, based on the total weight of the shaped abrasive composites.
    [001] In some embodiments, the nonionic polyether surfactant is present in an amount of 1.5 to 2.0 percent by weight, based on the total weight of the shaped abrasive composites. In some embodiments, shaped abrasive composites are precisely shaped. In some embodiments, the cross-linked polymeric binder comprises an acrylic polymer. In some embodiments, the surfactant comprises a segment of polyethylene oxide. In some embodiments, the surfactant comprises a segment of polypropylene oxide. In some embodiments, shaped abrasive composites additionally comprise an anionic phosphate polyether ester, the anionic phosphate polyether ester being present in an amount by weight that is less than that of the nonionic polyether surfactant.
    [002] In some embodiments, the backing layer comprises a polymeric film. In some of these embodiments, the polymeric film comprises an elastomeric polyurethane.
    [003] In some embodiments, the backing layer comprises a polymer foam. In some embodiments, the structured abrasive article further comprises a fastening interface layer connected directly to the second main surface. In some embodiments, the structured abrasive article further comprises a layer of pressure sensitive adhesive disposed on the second main surface.
    [004] In another aspect, the present description presents a method of abrasion of a workpiece comprising: putting in frictional contact at least a portion of the structured abrasive layer of the abrasive article structured according to the present description with a surface of a workpiece in the presence of an aqueous fluid, and moving at least one of the workpiece or the abrasive layer structured relative to one another to sand at least a portion of the workpiece surface.
    [005] Advantageously, abrasive articles structured in accordance with the present description can be used in abrasion processes that use only tap water instead of a surfactant solution. In addition, at least some of the structured abrasive articles exhibit improved abrasion properties (for example, cut rate and product life) when compared to products currently accepted by the industry. Brief Description of the Drawings Figure 1 is a cross-sectional side view of an exemplary structured abrasive article in accordance with the present description. Detailed Description
    [006] Now with reference to figure 1, an exemplary structured abrasive article 100, which has an abrasive layer 120 disposed on and attached to a first main surface 125 of the support layer 110. The abrasive layer 120 comprises precisely shaped abrasive composites 135. Each precisely shaped abrasive composite 135 comprises abrasive grains 140, optional crushing aid particles 145, and surfactant (not shown) dispersed in a polymeric binder 150. Each precisely shaped abrasive composite contains 2.5 to 3.5 percent, in weight, of a non-ionic polyether surfactant based on a total weight of the shaped abrasive composite. As shown in Figure 1, the optional attachment layer interface 160 is arranged on the second main surface 127 of the backing layer 110, and includes an optional pressure sensitive adhesive layer 170 and an optional loop fabric 175. optional loop 175 can be attached to the second main surface 127 by the optional pressure sensitive adhesive layer, if present, or by other direct contact bonding methods (eg heat laminating, needle bonding, ultrasonic welding ).
    [007] For use in the present invention, the term "shaped abrasive composite" refers to a body that comprises abrasive particles and a binder, and is intentionally formed in a non-random shape (for example, a pyramid, crest, etc. .), and typically characterized by regular contours. Exemplary training methods include casting and curing, embossing and molding methods. Shaped abrasive composites can be arranged on the backing layer according to a predetermined pattern (for example, as a matrix). In some embodiments, shaped abrasive composites are "precision molded". This means that the shape of the abrasive composites is defined by relatively smooth sides that are delimited and joined by well-defined edges whose lengths are distinct with distinct extreme points defined by the intersections of the various sides. The terms "delimited" and "contour" refer to the exposed surfaces and edges of each composite that delimit and define the actual three-dimensional shape of each abrasive composite. These contours are readily visible and discernible when the cross section of an abrasive article is viewed through a scanning electron microscope. These contours separate and distinguish a precisely shaped abrasive composite from any other, even when the composites fit together along a common edge at their bases. In terms of comparison, for an abrasive composite that does not have the precise shape, the contours and edges are not well defined (for example, when the abrasive composite is arched before it is cured).
    [008] Precisely shaped abrasive composites can have any three-dimensional shape that results in at least one prominent feature or recess in the exposed surface of the abrasive layer. Included as usable are, for example, the cubic, prismatic, pyramidal (for example, square pyramidal or hexagonal pyramidal), truncated, conical, frusto-conical pyramid. The combination of abrasive composites shaped and / or sized differently can also be used. The abrasive layer of the structured abrasive can be continuous or discontinuous.
    [009] Further details regarding structured abrasive articles having precisely shaped abrasive composites, and methods for their manufacture can be found, for example, in US patents No. 5,152,917 (Pieper et al.), 5,435,816 (Spurgeon et al. .), 5,672,097 (Hoopman), 5,681,217 (Hoopman et al.), 5,454,844 (Hibbard et al.), 5,851,247 (Stoetzel et al.), And 6,139,594 (Kincaid et al.) .
    [0010] Typically, shaped abrasive composites are arranged on the backing layer according to a predetermined pattern or arrangement, although this is not a requirement. Shaped abrasive composites can be arranged so that some of their work surfaces are chamfered from the polishing surface of the abrasive layer.
    [0011] For fine finishing applications, the density of abrasive composites conformed to the abrasive layer typically varies in the range of at least 150, 1,500, or even 7,800 abrasive composites per square centimeter (for example, at least 1,000, 10,000, or even 20,000 abrasive composites per square inch) up to and including 7,800, 11,000, or even up to 15,000 abrasive composites per square centimeter (up to and including 50,000, 70,000, or even up to 100,000 abrasive composites per square inch), although greater or lesser densities can also be employed of abrasive composites.
    [0012] In yet another embodiment, the structured abrasive article can be prepared by applying as a coating a fluid paste comprising a precursor of polymerizable binder, surfactant and abrasive grains through a screen that is in contact with a support layer. In this modality, the slurry is, then, typical and additionally polymerized (for example, through exposure to a source of energy), at the same time that it appears in the openings of the screen, thus forming a plurality of shaped abrasive composites that , in general, correspond to the shape of the screen openings. Further details related to this type of structured abrasive coated with canvas can be found, for example, in U.S. publication 2001/0041511 (Lack et al.).
    [0013] In another embodiment, a slurry comprising a precursor of polymerizable binder, surfactant, abrasive grains and a silane bonding agent can be deposited on a support layer in a standardized manner (for example, by silkscreen printing or by engraving), partially polymerized to cause at least the surface of the coated slurry to become plastic but not fluid, an embossed pattern on the partially polymerized slurry formulation, and subsequently to be further polymerized (for example, by exposure to a source of energy) to form a plurality of shaped abrasive composites affixed to the backing layer. General processes for preparing such embossed structured abrasive articles are described, for example, in US Patent No. 5,833,724 (Wei et al.), 5,863,306 (Wei et al.), 5,908,476 (Nishio et al. ), 6,048,375 (Yang et al.), 6,293,980 (Wei et al.), And in US patent application publication 2001/0041511 (Lack et al.).
    [0014] The structured abrasive article can have any shape, for example, round (for example, a disc), oval, or rectangular (for example, a sheet) depending on the particular shape of any support surface that can be used together with the article, or the article can form an endless mat. The structured abrasive article may contain openings or cracks and may be provided with perforations (for example, a perforated disc), and / or may have curvilinear edges.
    [0015] Individual shaped abrasive composites comprise abrasive grains and surfactants dispersed in a polymeric binder.
    [0016] Any abrasive granules known in the abrasion technique can be included in abrasive composites. Examples of useful abrasive grains include aluminum oxide, molten aluminum oxide, heat-treated aluminum oxide, ceramic aluminum oxide, silicon carbide, green silicon carbide, alumina, zirconia, ceria, iron oxide, garnet, diamond, cubic boron nitride, and combinations thereof. For repair and finishing applications, useful abrasive granule sizes are typically in the range of an average particle size of at least 0.01, 1, 3 or even 5 micrometers up to and including 35, 100, 250, 500, or even up to 1,500 micrometers, despite the fact that particle sizes outside this range can also be used Abrasive silicon carbide particles with a grade specified by the abrasives industry corresponding to sizes in the range of 3 to 7 micrometers are typically preferred shares. Typically, abrasive particles are included in the abrasive composites in an amount of 50 to 70 weight percent, based on the total weight of the shaped abrasive composites, although other amounts may also be used.
    [0017] Examples of polymeric binders that are useful in abrasive composites include thermoplastic resins such as polyesters, polyamides, and combinations thereof, heat hardened resins such as phenolic resins, aminoplast resins, urethane resins, resins epoxy, acrylic resins, isocyanurate resins with acrylate, cyanate resins, urea-formaldehyde resins, isocyanurate resins, urethane resins with acrylate, epoxy resins with acrylate, glue, and combinations thereof.
    [0018] In the case of heat-hardened resins, the binder is typically prepared by the polymerization and / or curing of a binder precursor. A preferred binder precursor is a resin or resin mixture that is polymerized via a free radical mechanism. The polymerization process is initiated by exposing the binder precursor, together with a suitable catalyst, to an energy source such as thermal energy or radiation energy. Examples of radiation energy include electron beam, ultraviolet light or visible light.
    [0019] Examples of curable free radical resins include acrylate urethanes, acrylate epoxies, acrylate polyesters, ethylenically unsaturated monomers, aminoplastic monomers with pendent unsaturated carbonyl groups, isocyanurate monomers with at least one pendant acrylate group, isocyanate monomers at least one pending acrylate group and mixtures and combinations thereof. For use in the present invention, the term "(meth) acrylate" encompasses acrylates and methacrylates, individually or in combination.
    An exemplary binder precursor comprises a urethane acrylate oligomer, or a blend of a urethane acrylate oligomer and an ethylenically unsaturated monomer. The preferred ethylenically unsaturated monomers are monofunctional (meth) acrylate monomers, difunctional (meth) acrylate monomers, trifunctional (meth) acrylate monomers or combinations thereof.
    [0021] Representative examples of ethylenically unsaturated monomers include (meth) methyl acrylate, (meth) ethyl acrylate, styrene, divinyl benzene, (meth) hydroxy ethyl acrylate, (meth) propyl hydroxy acrylate, (meth) acrylate hydroxy butyl, vinyl toluene, ethylene glycol di (meth) acrylate, polyethylene glycol di (meth) acrylate, hexane di (meth) acrylate, triethylene glycol di (meth) acrylate, trimethylol propane tri (meth) acrylate , glycerol tri (meth) acrylate, pentaerythritol tri (meth) acrylate, and pentaerythritol tetra (meth) acrylate. Other ethylenically unsaturated monomers or oligomers include monoalyl, polyallyl and polymethyl esters and amides of carboxylic acids, such as diallyl phthalate, diallyl adipate and N, N-diallyldamide. Still other nitrogen-containing compounds include tri (2-acryloxy ethyl) isocyanurate, 1,3,5-tri (2-methacryloxy ethyl) -s-triazine, acrylamide, methylacrylamide, N-methylacrylamide, N, N-dimethyl acrylamide, N- vinyl pyrrolidone, and N-vinyl pyrrolidone.
    [0022] Examples of commercially available acrylate urethanes include those known by the trade names: PHOTOMER (eg, PHOTOMER 6010 available from Henkel Corp. of Hoboken, NJ, USA, EBECRYL (eg, EBECRYL 220 (a urethane acrylate aromatic hexafunctional molecular weight 1000), EBECRYL 284 (1200 gram / mol aliphatic urethane diacrylate diluted with 1,6-hexane diol diacrylate), EBECRYL 4827 (1600 gram / mol aromatic urethane diacrylate) , EBECRYL 4830 (1200 gram / mol molecular aliphatic urethane diacrylate diluted with tetraethylene glycol diacrylate), EBECRYL 6602 (1300 gram / mol molecular weight trifunctional aromatic urethane acrylate diluted with trimethylol propane ethoxy triacrylate), and EBECRYL 840 (1000 gram / mol molecular aliphatic urethane diacrylate)) available from UCB Radcure of Smyrna, GA, USA, SARTOMER (eg SARTOMER 9635, 9645, 965 5, 963-B80, and 966-A80) available from Sartomer Co., West Chester, PA, USA, and UVITHANE (e.g., UVITHANE 782) available from Morton International, Chicago, IL, USA.
    [0023] Acrylate epoxies are acrylate esters of epoxy resins such as bisphenol A epoxy resin diacrylate esters. Examples of commercially available acrylate epoxies include those available as CMD 3500, CMD 3600, and CMD 3700 available from UCB Radcure, and as CN103, CN104, CN111, CN112, and CN114 available from Sartomer Co.
    [0024] Examples of polyester acrylates include those available as PHOTOMER 5007 and PHOTOMER 5018 available from Henkel Corp.
    [0025] Aminoplastic monomers have at least one alpha, beta pendant unsaturated carbonyl group. These unsaturated carbonyl groups can be groups of the acrylate, methacrylate or acrylamide type. Examples of such materials include N- (hydroxy methyl) -acrylamide, N, N'-oxymethylenebisacrylamide, ortho- and para-acrylamidomethylated phenol, acrylamidomethylated phenolic novolac, and combinations thereof.
    [0026] Depending on how it is cured or polymerized, the binder precursor may further comprise an effective amount of one or more curing agents (for example, catalyst (s), hardener (s), thermal initiator (s) ( s), and / or photoinitiator (s)) to cure the binder precursor, typically in amounts of up to about 10 weight percent of the binder precursor).
    [0027] In the case of free radical curing agents, when exposed to an adequate energy source, they generate free radicals that initiate polymerization. Free radical photoinitiators are typically preferred, and are widely known and available from suppliers such as Sartomer Corporation and Ciba Specialty Chemicals of Tarrytown, NY, USA. Exemplary photoinitiators include benzoin and its derivatives such as alpha-methylbenzoin, alpha-phenobenzoin, alpha-alolbenzoin, alpha-benzylbenzoin, benzoyl ethers such as benzyl dimethyl ketal (available, for example, as IRGACURE 651 from Ciba Specialty Chemicals), methyl ether of benzoin, benzoin ethyl ether, benzoin n-butyl ether, acetophenone and its derivatives such as 2-hydroxy-2-methyl-1-phenyl-1-propanone (available, for example, as DAROCUR 1173 from Ciba Specialty Chemicals), 1-hydroxy cyclohexyl phenyl ketone (available, for example, as IRGACURE 184 from Ciba Specialty Chemicals), 2-methyl-1- [4- (methylthio) phenyl] -2- (4-morpholinyl) -1-propanone (available , for example, as IRGACURE 907 from Ciba Specialty Chemicals), and 2-benzyl-2- (dimethylamino) -1- [4- (4-morpholinyl) phenyl] -1-butanone (available, for example, as IRGACURE 369 with Ciba Specialty Chemicals).
    [0028] Other useful photoinitiators include, for example, pivaloin ethyl ether, anisoin ethyl ether, anthraquinones (e.g., anthraquinone, 2-ethylanthraquinone, 1-chloroanthraquinone, 1,4-dimethylanthraquinone, 1-methoxyanthraquinone, or benzanthraquinone), halomethyl triazines, benzophenone and its derivatives, iodonium salts and sulfonium salts, titanium complexes such as bis (eta.sub.5-2,4-cyclopentadiene-1-ila) -bis [2,6-difluoro-3- ( 1H-pyrrol-1-yla-) phenyl] titanium (available, for example, as CGI 784DC from Ciba Specialty Chemicals), halomethyl nitrobenzenes (eg, 4-bromomethylnitrobenzene), mono- and bis-acylphosphines (eg, available with Ciba Specialty Chemicals under the trade names IRGACURE 1700, IRGACURE 1800, IRGACURE 1850, and DAROCUR 4265).
    [0029] One or more sensitizers (for example, dyes) can be added in combination with the photoinitiator, for example, to increase the sensitivity of a photoinitiator to a specific source of actinic radiation.
    [0030] Another binder precursor comprises an epoxy resin. Epoxy resins have oxirane rings that are polymerized by a ring opening reaction. Such epoxy resins include monomeric epoxy resins and polymeric epoxy resins. Examples of some preferred epoxy resins include 2,2-bis- 4- (2,3-epoxy propoxy) -phenyl) propane, a bisphenol diglycidyl ether, such as EPON 828, EPON 1004, and EPON 1001F available from Resolution Performance Products Houston, TX, USA, and as DER-331, DER-332, and DER-334 available from Dow Chemical Co. of Midland, MI, USA. Other suitable epoxy resins include cycloaliphatic epoxies, novolaca phenolic formaldehyde glycidyl ethers (eg DEN-431 and DEN-428), available commercially from Dow Chemical Co.
    [0031] Useful dressings for epoxy resins include, for example, diciandiamide and / or bis-imidazole.
    [0032] To promote an association bridge between the binder resin and the abrasive particles mentioned above, a silane bonding agent is included in the abrasive grain slurry and a solidifiable or polymerizable precursor, typically in an amount of about 0.01 to 5 percent by weight, more typically in an amount of about 0.01 to 3 percent by weight, more typically in an amount of about 0.01 to 1 percent by weight, although other amounts may also be used, for example depending on the size of the abrasive grains.
    [0033] Suitable silane bonding agents include, for example, gamma-methacryloxypropyl-trimethoxy-silane, vinyl triethoxy silane, tri (2-methoxy ethoxy) vinyl silane, 3,4-epoxy-cyclohexyl-methyl-trimethoxy silane, gamma- glycidoxypropyl trimethoxy silane, and gamma-mercapto propyl trimethoxy silane (for example, as available, respectively, as A-174, A-151, A-172, A-186, A-187, and A-189 from Dow Chemical Co.), allyl triethoxy silane, diallyl dichloro silane, divinyl diethoxy silane, in, p-estyril ethyl trimethoxy silane (for example, as available, respectively, as A0564, D4050, D6205, and S1588 from United Chemical Industries, Bristol, PA, USA), dimethyl diethoxy silane, dihydroxy diphenyl silane, triethoxy silane, trimethoxy silane, triethoxy silanol, 3- (2-aminoethylamino) propyl trimethoxy silane, methyl trimethoxy silane, vinyl triacethoxy silane, methyl triethoxy silane, tetraethyl ortho-ethyl tetramethyl orthosilicate, ethyl triethoxy silane, amyl triethoxy silane, ethyl trichloro silane, am il trichloro silane, phenyl trichloro silane, phenyl triethoxy silane, methyl trichloro silane, methyl dichloro silane, dimethyl dichloro silane, and similar compounds and mixtures thereof.
    [0034] Shaped abrasive composites can optionally contain additional ingredients such as dispersants, fillers, pigments, crushing aids, photoinitiators, hardeners, dressings, stabilizers, antioxidants, and photo-stabilizers.
    [0035] Suitable optional crushing aids include particulate material, the addition of which has a significant effect on the chemical and physical processes of abrasion, resulting in improved performance. In particular, a crushing aid can 1) decrease the friction between the abrasive grains and the workpiece being sanded, 2) prevent the abrasive grain from being “coated” (ie, prevent metal particles from being welded to the upper parts abrasive grains), 3) decrease the interface temperature between the abrasive grains and the workpiece, and / or 4) decrease the crushing forces. In general, the addition of a crushing aid increases the life of the coated abrasive. Crushing aids cover a wide variety of different materials and can be inorganic or organic.
    [0036] Examples of crushing aids include waxes, organic halide compounds, halide salts and metals and their alloys. Organic halide compounds will typically decompose during abrasion and release a halogen acid or a gaseous halide compound. Examples of such materials include chlorinated waxes such as tetrachloronaphthalene, pentachloronaphthalene, and polyvinyl chloride. Examples of halide salts include sodium chloride, potassium cryolite, sodium cryolite, ammonium cryolite, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluorides, potassium chloride, magnesium chloride. Examples of metals include tin, lead, bismuth, cobalt, antimony, cadmium, iron and titanium. Examples of other crushing aids include sulfur, organic sulfur compounds, graphite and metal sulfides. A combination of different crushing aids can also be used. The examples of crushing aids mentioned above are intended to be a representative sample of crushing aids and are not intended to cover all crushing aids.
    [0037] The amount of non-ionic polyether surfactant present in shaped abrasive composites is in the range of 2.5 to 3.5 percent by weight, based on the total weight of the shaped abrasive composites. For example, in some embodiments, the amount of non-ionic polyether surfactant present in shaped abrasive composites is in the range of 2.5 to 3.0 percent by weight, based on the total weight of the shaped abrasive composites. . In some embodiments, the amount of non-ionic polyether surfactant present in shaped abrasive composites is in the range of 2.8 to 3.2 percent by weight, based on the total weight of the shaped abrasive composites. For use in the present invention, the term "non-ionic polyether surfactant" refers to one or more non-ionic surfactants (ie, which do not have a permanent charge) that have a polyether segment, typically forming at least one portion of the surfactant main chain, although this is not a requirement. As is generally the case with surfactants, the nonionic polyether surfactant should not be covalently bonded to the cross-linked polymeric binder. To facilitate dissolution in the aqueous fluid, the nonionic polyether surfactant typically has a molecular weight in the range of 300 to 1200 grams per mol, although higher and lower molecular weights can be used.
    [0038] Examples of non-ionic polyether surfactants include polyoxyethylene alkyl ethers, polyoxyethylene alkylphenyl ethers, polyethylene ethyl esters, ethylene polyoxy alkylamines, ethylene polyoxy alkylamides, ethylene polyethyl lauryl ether, ether ether polyethylene ethylene, polyethylene ethyl stearyl ether, polyoxy ethylene oleyl ether, polyethylene ethyl octyl-phenolic ether, polyethylene ethylene non-phenyl ether, polyethylene glycol laurate, polyethylene glycol stearate, polyethylene glycol diestaerate, polyethylene oleate , oxyethylene-oxypropylene block copolymer, ethylene polyoxy sorbitan laurate, ethylene polyoxy sorbitan stearate, ethylene polyoxy sorbitan oleate, and ethylene polyoxide laurylamide.
    [0039] Useful nonionic polyether surfactants also include, for example, condensation products of a higher aliphatic alcohol with about 3 equivalents to about 100 equivalents of ethylene oxide (for example, those marketed by Dow Chemical Co. under the trade name TERGITOL 15-S such as, for example, TERGITOL 15-S-20, and those marketed by ICI Americas of Bridgewater, NJ, USA, under the BRIJ trade name, for example, BRIJ 58, BRIJ 76, and BRIJ 97). The BRIJ 97 surfactant is polyethylene ethyl ether (10), The BRIJ 58 surfactant is polyethylene ethyl cetyl ether (20), and the BRIJ 76 surfactant is polyethylene ethylene stearyl ether (10).
    [0040] Useful nonionic polyether surfactants may also include, for example, condensates of polyethylene oxide of an alkyl phenol with about 3 equivalents to about 100 equivalents of ethylene oxide (for example, those marketed by Rhodia de Cranbury, NJ, USA, under the trade names IGEPAL CO and IGEPAL CA). CO surfactants include nonylphenoxy poly (ethylene-oxy) ethanols. CA surfactants include poly (ethylene-oxy) octylphenoxy ethanols.
    [0041] Useful nonionic polyether surfactants also include, for example, block copolymers of ethylene oxide and propylene oxide or butylene oxide (for example, those marketed by BASF Corp. of Mount Olive, NJ, USA, under the trade names PLURONIC (eg PLURONIC L10) and TETRONIC). PLURONIC surfactants can include polymers of propylene oxide, polymers of ethylene oxide and block copolymers of ethylene oxide-propylene oxide. Surfactants include block copolymers of ethylene oxide and propylene oxide.
    [0042] Useful nonionic polyether surfactants also include, for example, polyoxyethylene sorbitan fatty acid esters (eg, polyoxyethylene sorbitan monooleates, which may have different degrees of ethoxylation, such as 20 units of oxide ethylene per molecule (for example, marketed as TWEEN 60) or 20 units of ethylene oxide per molecule (for example, marketed as TWEEN 80)) and ethylene polyoxy stearates (for example, those marketed under the trade names TWEEN and MYRJ by the Uniqema of New Castle, DE, USA). TWEEN surfactants include C12-C18 sorbitan monoesters of poly (ethylene oxide). Surfactants include poly (ethylene oxide) stearates.
    [0043] In some embodiments, the nonionic polyether surfactant is the only surfactant present in shaped abrasive composites or in the aqueous fluid during abrasion. In some cases, it may be desirable to add smaller amounts of anionic surfactants such as an anionic phosphate polyether ester available as TRITON H55 from Dow Chemical Co.
    [0044] Useful support layers include, for example, film support layers and foam support layers.
    [0045] Suitable film support layers include polymeric films and polymeric films coated with a base (primer), specifically those used in abrasion techniques. Useful polymeric films include, for example, polyester films (for example, an ethylene acrylic acid copolymer coated with polyethylene terephthalate), polyolefin films (for example, polyethylene or polypropylene films), and elastic polyurethane films. The backing layer of the film may be a laminate of two polymeric films. Examples of elastomeric polyurethanes that can be used to form films include those available under the trade name ESTANE from BF Goodrich and Co. of Cleveland, OH, USA, and those described in U.S. Patent No. 2,871,218 (Schollenberger), 3,645. 835 (Hodgson), 4,595,001 (Potter et al.), 5,088,483 (Heinecke), 6,838,589 (Liedtke et al.), And RE 33,353 (Heinecke). Polyurethane elastomer films coated with pressure sensitive adhesive are commercially available from 3M Company under the trade name TEGADERM. Useful polymeric films generally have thicknesses ranging from about 0.02 to about 0.5 mm, for example, from 0.02 millimeter to 0.1 millimeter in thickness, although this is not a requirement.
    [0046] Useful polymeric foams include open-cell and closed-cell polymeric foams, typically compressible and resilient. Useful polymeric foams include elastic foams such as chloroprene-based rubber foams, ethylene / propylene-based rubber foams, butyl rubber foams, polybutadiene foams, polyisoprene foams, EPDM polymer foams, polyurethane, ethylene - vinyl acetate foams, neoprene foams and styrene / butadiene copolymer foams. Usable foams further include thermoplastic foams such as polyethylene foams, polypropylene foams, polybutylene foams, polystyrene foams, polyamide foams, polyester foams, plasticized poly (vinyl chloride) foams (ie PVC). Examples of useful open cell foams include polyurethane foams with polyester available from Illbruck, Inc. of Minneapolis, MN, USA, under the trade names R 200U, R 400U, R 600U and EF3-700C.
    [0047] Useful foam support layers generally have thicknesses ranging from about 1 to about 15 mm, although this is not a requirement.
    [0048] The support layer can have a fixation interface layer on its back surface to fix the abrasive article on a support or support surface. Such an intermediate fastening system can be, for example, a pressure sensitive adhesive or tape, a loop fabric for a hook and loop fastening, a hook structure for a hook and loop fastening, or an interlacing fastening system. Further details regarding such fastening systems can be found, for example, in US patents No. 5,152,917 (Pieper et al.), 5,454,844 (Hibbard et al.), 5,672,097 (Hoopman), 5,681,217 (Hoopman et al.), And in US patent application publications numbers 2003/0143938 A1 (Braunschweig et al.) And 2003/0022604 A1 (Annen et al.).
    [0049] Structured abrasive articles (specifically those having precisely shaped abrasive composites) can be prepared by forming a slurry of abrasive grains and a solidifiable or polymerizable precursor of the aforementioned binder resin (ie, a binder precursor), placing the slurry is in contact with the support layer and the binder precursor solidifies and / or polymerizes (for example, by exposure to an energy source) so that the resulting structured abrasive article has a plurality of shaped abrasive composites affixed to the backing layer. Examples of energy sources include thermal energy and radiation energy (for example, including electron beam, ultraviolet light and visible light).
    [0050] For example, in some embodiments, the slurry can directly coat a production tool containing precisely shaped cavities and be placed in contact with the support layer, or cover the support layer and be placed in contact with the production. In this embodiment, the slurry is then typically solidified or cured at the same time that it is present in the cavities of the production tool.
    [0051] The choice of curing conditions typically depends on the specific binder precursor used, and is within the capacity of the element skilled in the art. In general, it is important that a substantially complete cure is obtained to provide all the benefits of the present description. That is, additional curing at the same temperature and / or wavelengths does not substantially alter the abrasive properties. At lower degrees of cure, abrasive composites tend to decompose more quickly and less surfactant is, in general, necessary; however, the overall abrasive properties are generally degraded under such lower degrees of cure.
    [0052] Typically, a period of time (for example, at least about 24 hours) is waited before the structured abrasive article is used in abrasion processes, although this is not a requirement. In some cases, the abrasion performance can be reduced if the structured abrasive article is used in abrasion processes before such an aging period.
    [0053] The workpiece can comprise any material and can have any shape. Examples of suitable materials include ceramics, paint, thermoplastic or thermoset polymers, polymeric coatings, polycrystalline silicon, wood, marble, and combinations thereof. Examples of substrate shapes include molded and / or shaped articles (for example, optical lenses, car body panels, boat hulls, counters and sinks), inserts, sheets and blocks. The methods according to the present description are particularly useful for repairing and / or polishing polymeric materials such as motor vehicle paint finishes and resins (for example, automotive finish resins), examples of which include: polyacrylic-polyol-polyisocyanate compositions ( for example, as described in US patent No. 5,286,782 (Lamb, et al.), acrylic hydroxyl-polyol-polyisocyanate function compositions (for example, as described in US patent No. 5,354,797 (Anderson, et al. ), polyisocyanate-carbonate-melamine compositions (for example, as described in US Patent No. 6,544,593 (Nagata et al.), and high-polysiloxane solids compositions (for example, as described in US Patent No. 6,428. 898 (Barsotti et al.)) A suitable finishing resin comprises nanometer sized silica particles dispersed in a crosslinked polymer.An example of this finishing resin is available as CERAMICLEAR from PPG Industries from Pittsburgh, PA, USA. Other suitable materials that can be repaired and / or polished in accordance with the present description include marine gel coatings, polycarbonate lenses, counter surfaces and sinks produced from synthetic materials such as those marketed as DUPONT CORIAN by EI du Pont de Nemours and Company of Wilmington, DE, USA.
    [0054] In the typical use of abrasive articles structured according to the present description, the abrasive layer is placed in frictional contact with a surface of a workpiece and then at least one of the structured abrasive article or the workpiece it is moved relative to each other to sand at least a portion of the workpiece. To facilitate the removal of chips (ie loose dust and debris generated during abrasion of the workpiece) from the surface, the process is carried out in the presence of an aqueous fluid. For use in the present invention, the term "aqueous" means containing at least 30 weight percent water). Typically, the liquid comprises at least 90 or even at least 95 weight percent water. For example, the liquid may comprise (or consist of) municipal water or well water. During abrasion, the aqueous liquid will contain a nonionic polyether surfactant that dissolves from the structured abrasive article. Without sticking to the theory, it is believed that this reduces the adverse filing load (for example, the accumulation of filings between adjacent shaped abrasive composites) of the structured abrasive article and facilitates the erosion of shaped abrasive composites, which increases the service life cutting.
    [0055] If desired, in addition to water the aqueous fluid may contain additional components such as, for example, water-miscible organic solvents (for example, alcohols such as ethanol, 2-ethoxy ethanol and including polyols such as propylene glycol and / or polyethers such as diglima), surfactants and crushing aids. Advantageously, the aqueous fluid may be free of additional surfactant in addition to the nonionic polyether surfactant, although this is not a requirement. In practice, the aqueous fluid can be applied to the workpiece surface, the abrasive layer, or both.
    [0056] The structured abrasive article can be moved in relation to the workpiece manually or by mechanical means such as, for example, an electric or pneumatic motor using any method known in the abrasion technique. The structured abrasive article can be removably attached to a support surface (for example, as is common practice with discs) or can be used without a support surface (for example, in the case of abrasive belts).
    [0057] Once the abrasion is completed with the use of the structured abrasive article, the workpiece is typically rinsed (for example, with water) to remove residues generated during the abrasion process. After rinsing, the workpiece can be further polished with the use of a polishing compound, for example, together with a smoothing block. This optional polishing compound typically contains fine abrasive particles (for example, with an average particle size less than 100 micrometers, less than 50 micrometers, or even less than 25 micrometers) in a liquid vehicle. Other details related to polishing compounds and processes are described, for example, U.S. Patent Application Publication No. 2003/0032368 (Hara).
    [0058] The objectives and advantages of this description are further illustrated by the following non-limiting examples, but the specific materials and proportions of them cited in these examples, as well as other conditions and details, should not be interpreted as undue limiting of this description. Examples
    [0059] Except where otherwise specified, all parts, percentages, ratios, etc., in the examples and the rest of the specification are by weight.
    [0060] The following abbreviations are used in the examples below: “ABR1” refers to a structured abrasive disk having an abrasive layer composed of a displaced compacted matrix of tetrahedral abrasive composites, each having a base width of 92 micrometers, one height of 63 micrometers, and composed of abrasive grains of green silicon carbide (4.0 micrometers of average particle size) dispersed in a polymeric binder, obtained as “3M TRIZACT FILM 466LA, A5 DISC” available from 3M Company de Saint Paul, MN, USA; “ABR2” refers to a structured abrasive disk having an abrasive layer of alternating compacted pyramidal matrices of helical cut of 34 degrees, with 11 by 11 rows with a base width of 83.8 by 83.8 micrometers (3.3 mils by 3.3 mils) by 63.5 micrometers (2.5 mils) deep, separated by 3 by 3 rows of the same truncated pyramid matrix at a depth of 21 micrometers (0.83 mil), and composed of abrasive grains of green silicon carbide (4.0 micrometers of average particle size) dispersed in a polymeric binder, the article being obtained under the trade name “3M TRIZACT FILM 460LA, A5 DISC” available from 3M Company; "ABR3" to "ABR7" refer to structured abrasive discs produced in general according to the procedure described in Examples 1-5 and in the amounts of surfactant indicated in Table 1; "ACR1" refers to 2-phenoxy acrylate, commercially available as SR339 from Sartomer Co. of Exton, PA, USA; “ACR2” refers to trimethylol propane triacrylate, commercially available as SR351 from Sartomer Company; “AD1” refers to a secondary alcoholic ethoxylate (5 moles of ethylene oxide) (non-ionic polyether surfactant) available as TERGITOL 15-S-5 from Dow Chemical Corp. Midland, MI, USA; “CPA1” refers to gamma-methacryloxypropyl-trimethoxy-silane, available as A-174 from Crompton Corp. Middlebury, CT, USA; “MIN1” refers to the green silicon carbide mineral, D50 = 4.0 micrometers, available as GC 3000 GREEN SILICON CARBIDE from Fujimi Corp. from Tualatin, OR, USA; “MIN2” refers to the green silicon carbide mineral, D50 = 5.5 micrometers, available as GC 2500 GREEN SILICON CARBIDE from Fujimi Corp. "FIL" refers to pyrolyzed silica, commercially available under the trade name OX-50 from The Cary Company of Addison, IL, USA; “DSP1” refers to an anionic polyester dispersant, obtained under the trade name SOLPLUS D520 from Lubrizol Advanced Materials of Cleveland, OH, USA; “TP1” refers to a car panel for finishing resin testing available as GEN IV AC from Du Pont Automotive of Troy, MI, USA, and “UVI1” refers to an acylphosphine oxide available as LUCERIN TPO -L with BASF Corp. from Florham Park, NJ, USA. Cutting life test
    [0061] The cutting life test was performed as follows: A disc having a diameter of 3.18 cm (1.25 inches) from the indicated abrasive article was glued to a foam support surface with a vinyl face. 12.7 cm (5 inches) by 3.18 cm (1.25 inches) thick, available as 3M FINESSE-IT STIKIT BACKUP PAD from 3M Company. The support surface was mounted on an orbital sander for fine finishing, available as DYNABRADE MODEL 59025 from Dynabrade, Inc. of Clarence, NY, USA.
    [0062] For Example 6 and the comparative examples LM, a hook fastener available as the hooked adhesive portion on the back of a 3M SCOTCHMATE hook and loop fastener available from 3M Company, cut into a disc of 3.2 cm (1.25 inches) in diameter, was attached to a support surface available as 3M STIKIT ROLOC DISC PAD 02727, 3.2 cm (1 1/4 inches) x 0.8 cm (5/16 inch) available from 3M Company using the adhesive layer over the adhesive portion with hook on the back, and used as a support surface instead of the 3M FINESSE-IT STIKIT BACKUP PAD block.
    [0063] The abrasive layer of the disc was then nebulized with water in an amount sufficient to cover the entire surface of the abrasive layer with the use of 1 or 2 jets of liquid from a 0.71 liter (24 fluid ounces) spray bottle ). The abrasive layer was manually contacted with a surface coated with finishing resin from the TP1 workpiece, which was then sanded for 3 to 5 seconds at 7,500 revolutions per minute (rpm) at a pressure of 621 kilopascals (90 psi) and a zero degree angle (ie, kept manually flat in relation to the workpiece surface). The nebulization and figuration steps were repeated in adjacent areas of the test panel until the abrasive disc became clogged with debris, as visually indicated by the incomplete removal of the finishing resin. The number of times the abrasive wheel could be used without obstruction (ie the number of cycles) was reported as the cutting life of the abrasive wheel. Examples 1 to 5 and Comparative Examples A and B
    [0064] ABR3 - ABR7 abrasive pastes were prepared as follows: 15.8 parts ACR1, 15.8 parts ACR2, 0.71 part DSP1, 1.94 parts CPA1, 1.1 parts UVI1, 1.64 parts of FIL, surfactant AD1 in the amounts indicated in Table 1, and 60 parts of MIN1 were homogeneously dispersed for one hour with the use of a mechanical mixer at a temperature above 30 ° C.
    [0065] Each slurry was applied by means of cut coating to a micro-replicated polypropylene matrix 30.5 cm (12 inches) wide having a helical cut alternating between 34 degrees, uniformly and compactly distributed, pyramidal matrices having 11 per 11 rows with a base width of 83.8 by 83.8 micrometers (3.3 mils by 3.3 mils) by 63.5 micrometers (2.5 mils) deep, separated by 3 by 3 rows of the same matrix truncated pyramid at a depth of 21 micrometers (0.83 mil), as shown in Figure 2 of US Patent No. 7410413 (Woo et al.). The tool was prepared from a corresponding master tool, generally in accordance with the procedure of U.S. Patent No. 5,975,987 (Hoopman et al.). The polypropylene matrix filled with slurry was then placed in a blanket of polyester film prepared with ethylene acrylic acid 30.5 cm (12 inches) wide, 94.2 micrometers (3.71 mil) thick , obtained as MA370M available from 3M Company, passed through a choke cylinder (with pressure in the 620.5 kilopascals (kPa) contact line (90 pounds per square inch (psi)) to a 25.4 cm blanket (10 inches) wide), and was irradiated with an ultraviolet (UV) lamp, type “D” lamp, available from Fusion Systems Inc., Gaithersburg, Maryland, USA, at 236 Watts / cm (600 Watts / inch) during the movement of the blanket at 9.14 meters / minute (30 feet / minute (fpm)). The polypropylene mold was separated from the polyester film prepared with ethylene acrylic acid, resulting in a fully cured, precisely shaped abrasive layer adhered to the polyester film prepared with ethylene acrylic acid. The pressure sensitive adhesive was laminated to the back (opposite to the abrasive layer) of the backing layer. The disks (3.18-cm (1.25 inches) in diameter) were then die cut from the structured abrasive article.
    [0066] The structured abrasive articles were prepared as reported in Table 1. The results of the cutting life test for the corresponding structured abrasive articles are shown in Table 1 (below).
    Example 6 and Comparative Examples C - D
    [0067] ABR8-ABR10 abrasive pastes were prepared as follows: 1.08 parts of UVI1, 3.08 parts of DSP1, 1.92 parts of CPA1, 19.48 parts of ACR2, 12.94 parts of ACR1, surfactant AD1 in the amounts indicated in Table 2, and 68.5 parts of MIN2 were dispersed homogeneously for approximately 60 minutes using a laboratory mixer with a Cowles blade. This slurry was applied by cutting coating to a 30.5 cm (12 inch) wide micro-replicated polypropylene matrix showing the repetition pattern shown in Figures 14 and 15 of US Patent No. 6,923,840 (Schutz et al.). The tool was prepared from a corresponding master tool, generally in accordance with the procedure of U.S. Patent No. 5,975,987 (Hoopman et al.). The polypropylene matrix filled with slurry was then placed in a choke cylinder in contact with a 2.3 mm (0.090 inch) thick piece of R600U foam available from Pinta Foamtec, Minneapolis, MN, USA . The surface of the R600U foam placed in contact with the slurry had been spray-coated with Hycar 2679 available from Lubrizol Corporation of Wickliffe, OH, USA, at a dry coating weight of about 88.9 g / m2 (8 grams) /square foot.). The opposite side of the foam contained a white fabric backing layer (HI / Know 94 backing layer available from 3M Company) and was laminated adhesive to the foam surface.
    [0068] The construction consisting of the polypropylene matrix, the slurry and the foam was then passed through a choke cylinder (with pressure on the contact line of 413 kilopascals (kPa) (60 pounds per square inch (psi) ) for a 20.3 cm (8 inch) wide blanket), and was irradiated with a type “D” ultraviolet (UV) lamp, available from Fusion Systems, Inc. of Gaithersburg, Maryland, USA, at 236 Watts / cm (600 Watts / inch) when moving the blanket at 21.33 meters / minute (70 feet / minute (fpm)). The polypropylene was separated from the foam, resulting in a precisely shaped abrasive layer adhered to portions of the foam. Discs with a diameter of 3.18 cm (1.25 inches) were then die cut from the structured abrasive article. The cutting life test was conducted as described above.

    [0069] All patents and publications presented here are incorporated by reference in their entirety. Various modifications and alterations not contemplated in the present description can be made by those skilled in the art without departing from the scope and spirit of the present description, and it should be understood that the present description should not be unduly limited to the illustrative modalities presented here.
    权利要求:
    Claims (14)
    [0001]
    1. Structured abrasive article CHARACTERIZED by the fact that it comprises: a support layer containing a first and a second opposing main surface, and a structured abrasive layer arranged on and attached to a first main surface, the structured abrasive layer comprising shaped abrasive composites, where shaped abrasive composites comprise abrasive particles and a nonionic polyether surfactant dispersed in a cross-linked polymeric binder, where the abrasive particles have an average particle size of less than 10 micrometers, where the nonionic polyether surfactant is not covalently attached to the cross-linked polymeric binder, and in which the nonionic polyether surfactant is present in an amount of 2.5 to 3.5 percent by weight, based on the total weight of the shaped abrasive composites.
    [0002]
    2. Structured abrasive article, according to claim 1, CHARACTERIZED by the fact that the nonionic polyether surfactant is present in an amount of 2.8 to 3.2 percent by weight, based on a total weight of conformed abrasive composites
    [0003]
    3. Structured abrasive article, according to claim 1, CHARACTERIZED by the fact that shaped abrasive composites are precisely molded.
    [0004]
    4. Structured abrasive article, according to claim 1, CHARACTERIZED by the fact that the cross-linked polymeric binder comprises an acrylic polymer.
    [0005]
    5. Structured abrasive article, according to claim 1, CHARACTERIZED by the fact that the surfactant comprises a polyethylene oxide segment.
    [0006]
    6. Structured abrasive article, according to claim 1, CHARACTERIZED by the fact that the surfactant comprises a polypropylene oxide segment.
    [0007]
    7. Structured abrasive article according to claim 1, CHARACTERIZED by the fact that shaped abrasive composites additionally comprise an anionic phosphate polyether ester, in which the anionic phosphate polyether ester is present in an amount, by weight, which is less than that of the nonionic polyether surfactant.
    [0008]
    8. Structured abrasive article according to claim 1, CHARACTERIZED by the fact that the backing layer comprises a polymeric film.
    [0009]
    9. Structured abrasive article, according to claim 8, CHARACTERIZED by the fact that the polymeric film comprises an elastomeric polyurethane.
    [0010]
    10. Structured abrasive article according to claim 1, CHARACTERIZED by the fact that the backing layer comprises a polymer foam.
    [0011]
    11. Structured abrasive article according to claim 1, CHARACTERIZED by the fact that the structured abrasive article further comprises a fastening interface comprising a pressure sensitive adhesive layer disposed on the second main surface.
    [0012]
    12. Structured abrasive article according to claim 1, CHARACTERIZED by the fact that the structured abrasive article further comprises a fastening interface layer comprising a loop fabric.
    [0013]
    13. Method of abrasion of a workpiece, the method CHARACTERIZED by the fact that it comprises: putting in frictional contact at least a portion of the structured abrasive layer of the structured abrasive article, as defined in claim 1, with a surface of a workpiece work while in the presence of an aqueous fluid, and move at least one of the workpiece or the abrasive layer structured relative to one another to abrasion at least a portion of the workpiece surface.
    [0014]
    14. Method, according to claim 13, CHARACTERIZED by the fact that the aqueous fluid consists of municipal water or well water.
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    法律状态:
    2018-04-17| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2020-11-10| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-01-05| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 10 (DEZ) ANOS CONTADOS A PARTIR DE 05/01/2021, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US12/560.797|2009-09-16|
    US12/560,797|US8348723B2|2009-09-16|2009-09-16|Structured abrasive article and method of using the same|
    PCT/US2010/029553|WO2011034635A1|2009-09-16|2010-04-01|Structured abrasive article and method of using the same|
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